Systems, methods and apparatus for providing to a driver of a vehicle carrying a mixture real-time information relating to a characteristic of the mixture

ABSTRACT

Information relating to a change made to a concrete mixture in a concrete mixer truck is obtained. An expected value of a selected characteristic of the concrete mixture is determined based on the change. A representation of the expected value is displayed on a processing device located in a cab of the concrete mixer truck. In one embodiment, the mixture comprises a concrete mixture. The change may comprise an addition of water to the mixture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/864,107, filed on Sep. 24, 2015, which is a continuation of U.S.application Ser. No. 14/194,293, filed on Feb. 28, 2014, the priority ofwhich is claimed and the contents of each are incorporated herein byreference.

TECHNICAL FIELD

This specification relates generally to real-time systems and methodsfor managing data, and more particularly to systems and methods forproviding to a driver of a vehicle carrying a mixture real-timeinformation relating to a characteristic of the mixture.

BACKGROUND

In many industries, consumers order a product based on a specification,and subsequent to their order, the product is manufactured based on aformulation that specifies a plurality of components and a particularmethod, procedure, or recipe to be followed. Once the product is made,it is shipped by the producer to the consumer. In such industries wherean order is placed prior to manufacturing, orders are based on expectedcharacteristics and costs of the product. When the product is made at alater date, it is important that the product be made and deliveredaccording to the expected characteristics and costs.

In practice, however, changes often occur during the manufacturing andshipping process due to a variety of factors, such as an unavailabilityof components, a failure to include the correct quantity of a componentspecified in the recipe, or the addition of a component that is notlisted in or is consistent with the formulation. Such changes may occurdue to human error, either accidental or deliberate, or due toformulations being maintained in a non-normalized fashion such as inmultiple disconnected systems, or due to malfunction of a deviceinvolved in the production system, or due to unforeseen events.Furthermore, a component specified in the formulation may be incorrectlybatched, or knowingly or unknowingly replaced with assumed equivalentcomponents because the raw materials are not available, or for otherreasons. One well known example is the use of either sucrose or highfructose corn syrup in soft drinks. Typically, during production of asoft drink, one of these two sweeteners is selected and used dependingupon the cost and availability of the sweetener at the time when thesoft drink product is manufactured.

Similar practices are used in the ready mix concrete industry. A givenmixture of concrete, defined by a particular formulation (specifyingtypes of components and quantities thereof), may be produced differentlyat different production facilities and/or at different times, dependingon a variety of factors. For example, the types and quantities of cementand Pozzolanic cementitious materials, chemicals, different types ofaggregates used often varies between batches, due to human error, or forreasons which may be specific to the time and location of production.Some components may not be available in all parts of the world, acomponent may be incorrectly batched, components may be replaceddeliberately or accidentally, etc. Furthermore, in the ready mixconcrete industry, it is common for changes in the mixed composition tooccur during transport of the product. For example, water and/orchemicals may be added due to weather, or due to the length of timespent in transit to the site where the ready mix concrete is poured, ordue to customer demands. Changes to a mixture may also occur during thebatching process. For example, an incorrect amount of a criticalcomponent such as water or cementitious may be added. Similarly, anincorrect amount of fly ash or other pozzolans, such as slag, may beused to make the cementitious portion. Furthermore, it is commonindustry practice to make certain changes to a concrete mixture whilethe mixture is being transported in a mixer truck. For example, thedriver may add water at various stages during transport. Such practicesmay be prone to human error.

Due to the reasons set forth above, a customer often receives a productwhich differs from the product ordered. The quality of the product maynot meet expectations. Furthermore, any change made to a product mayimpact the producer's cost and profits.

In addition, in many industries, various activities important to aproducer's business, such as sales, purchasing of raw materials,production, and transport, are conducted independently of one another.The disjointed nature of the sales, purchasing of raw materials,production, and transport creates an additional hindrance to theproducer's, and the customer's, ability to control the quality and costof the final product.

Accordingly, there is a need for improved production management systemsthat provide, to producers and to customers, greater control overvarious aspects of the production system used to produce a product, andthereby provide greater control over quality and costs.

SUMMARY

In accordance with an embodiment, a method of managing information isprovided. Information relating to a change made to a concrete mixture ina concrete mixer truck is obtained. For example, the change may comprisean addition of water to the mixture. An expected value of a selectedcharacteristic of the concrete mixture is determined based on thechange. A representation of the expected value is displayed on aprocessing device located in a cab of the concrete mixer truck. Forexample, a difference value representing a difference between theexpected value and a design value may be displayed in the form of agauge on a computer, or as an App (referred to herein as an App or Appdisplay) on an Android or Apple smart phone or Tablet, used by thedriver of the truck.

In various embodiments, the characteristic comprises one of a quantityof water in the mixture, a strength of the mixture, a slump of themixture, a standard deviation of strength, a standard deviation ofslump, a quantity of cementitious in the mixture, and a cost measureassociated with the mixture.

In another embodiment, the concrete mixture is produced based on aformulation. A graphical representation of a gauge is displayed, whereinan indicator of the gauge indicates a difference between the expectedvalue and a second value of the characteristic determined based on theformulation.

In accordance with another embodiment, a method of managing informationis provided. A change made to a mixture during transport of the mixturein a vehicle is determined, wherein the mixture is associated with aformulation. An expected measure of a characteristic of the mixture isdetermined based on the change. A desired measure of the characteristicis determined based on the formulation. A difference value representinga difference between the expected measure and the desired measure isdetermined. The difference value is transmitted to a communicationdevice disposed in the vehicle. The communication device is caused todisplay the difference value.

In one embodiment, the mixture comprises a concrete mixture, and thevehicle comprises a concrete mixer truck.

In another embodiment, the change comprises one of an addition of waterand an addition of a chemical.

In another embodiment, the change comprises a first addition of a firstquantity of water to the mixture. Information relating to a secondaddition of a second quantity of water to the mixture is received. Theexpected measure of the characteristic of the mixture is determinedbased on the change and the second addition of water.

In another embodiment, the characteristic comprises one of a quantity ofwater in the mixture, a strength of the mixture, a slump of the mixture,a standard deviation of strength, a standard deviation of slump, aquantity of cementitious in the mixture, and a cost measure associatedwith the mixture.

In another embodiment, determining an expected measure of acharacteristic of the mixture based on the change comprises examininghistorical data relating to the effect of the change on thecharacteristic.

In another embodiment, the communication device is caused to display agraphical representation of a gauge, wherein an indicator of the gaugeindicates the difference value.

In another embodiment, the communication device displays a shaded regionon the gauge, the shaded region representing a range of differencevalues within acceptable tolerances.

In accordance with another embodiment, a system includes at least onememory storing computer program instructions. The system also includesat least one processor configured to execute the computer programinstructions which, when executed on the at least one processor, causethe at least one processor to perform operations including obtaining,from a device in a vehicle, information relating to a change made to amixture while the mixture is being transported in the vehicle,determining an expected value of a selected characteristic of themixture based on the change, and causing a communication device locatedin the vehicle to display a representation of the expected value.

These and other advantages of the present disclosure will be apparent tothose of ordinary skill in the art by reference to the followingDetailed Description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a product management system in accordance with anembodiment;

FIG. 1B shows an exemplary menu that may be presented to a customer inaccordance with an embodiment;

FIG. 1C is a flowchart of a method of managing a production system inaccordance with an embodiment;

FIG. 2 is a flowchart of a method of producing a mixture in accordancewith an embodiment;

FIG. 3 is a flowchart of a method of handling an order received from aproduction facility in accordance with an embodiment;

FIG. 4 illustrates a method of responding to an alert when a productionfacility replaces an ingredient with a known equivalent, in accordancewith an embodiment;

FIG. 5 is a flowchart of a method of responding to an alert indicating adifference between a batched quantity and a specified quantity inaccordance with an embodiment;

FIG. 6 is a flowchart of a method of managing transport-related data inaccordance with an embodiment;

FIG. 7A shows a production management system in accordance with anotherembodiment;

FIG. 7B shows a production management system in accordance with anotherembodiment;

FIG. 7C shows a production management system in accordance with anotherembodiment;

FIG. 8 illustrates a system for the management of localized versions ofa mixture formulation in accordance with an embodiment;

FIG. 9 is a flowchart of a method of generating localized versions of amixture formulation in accordance with an embodiment;

FIG. 10 shows a mixture formulation and several localized versions ofthe mixture formulation in accordance with an embodiment;

FIGS. 11A-11B illustrate a system for synchronizing versions of amixture formulation in accordance with an embodiment;

FIG. 12 is a flowchart of a method of synchronizing a localized versionof a mixture formulation with a master version of the mixtureformulation in accordance with an embodiment;

FIGS. 13A-13B comprise a flowchart of a method of managing a closed-loopproduction system in accordance with an embodiment;

FIG. 14 shows an exemplary web page that displays information relatingto purchase, production and delivery of a mixture in accordance with anembodiment;

FIG. 15 shows a production management system in accordance with anotherembodiment;

FIGS. 16A-16B comprise a flowchart of a method of producing andanalyzing a mixture in accordance with an embodiment;

FIG. 17 is a flowchart of a method of producing a formulation-basedmixture in accordance with an embodiment;

FIG. 18 is a flowchart of a method of determining a measure of concretestrength performance quality for concrete produced at a productionfacility in accordance with an embodiment;

FIGS. 19A-19B comprise a flowchart of a method of providing comparativestatistical information relating to a plurality of production facilitiesin accordance with an embodiment;

FIG. 20 shows a web page containing statistical information for aplurality of production facilities in accordance with an embodiment;

FIG. 21 shows a production management system in accordance with anotherembodiment;

FIG. 22 shows a vehicle carrying a mixture in accordance with anembodiment;

FIG. 23 shows components of a user device in accordance with anembodiment;

FIG. 24 is a flowchart of a method of managing information in accordancewith an embodiment;

FIGS. 25-29 show web pages or Apps displaying gauges which showinformation related to a mixture in accordance with various embodiments;

FIG. 30 is a flowchart of a method of managing information in accordancewith an embodiment;

FIG. 31 shows a web page or App displaying a gauge which showsinformation related to a mixture in accordance with an embodiment; and

FIG. 32 is a high-level block diagram of an exemplary computer that maybe used to implement certain embodiments.

DETAILED DESCRIPTION

In accordance with embodiments described herein, systems and methods ofmanaging a closed-loop production management system used for productionand delivery of a formulation-based product are provided. Systems,apparatus and methods described herein are applicable to a number ofindustries, including, without limitation, the food manufacturingindustry, the paint industry, the fertilizer industry, the chemicalsindustry, the oil refining industry, the pharmaceuticals industry,agricultural chemical industry and the ready mix concrete industry.

In accordance with an embodiment, a method of managing a closed loopproduction system is provided. An order relating to a formulation-basedproduct is received, wherein fulfilling the order requires production ofthe formulation-based product at a first location, transport of theformulation-based product in a vehicle to a second location differentfrom the first location, and performance of an activity with respect tothe formulation-based product at the second location. First informationrelating to a first change made to the formulation-based product at thefirst location is received, from the first location, prior to transportof the formulation-based product. Second information relating to asecond change made to the formulation-based product during transport ofthe formulation-based product is received during transport of theformulation-based product. Third information relating to the activityperformed with respect to the formulation-based product at the secondlocation is received from the second location. The first, second, andthird information are stored in a data structure, and may be displayedwith an analysis of the impact of selected information on the cost ofthe product.

In one embodiment, the processor operates within a product managementsystem comprising a plurality of modules operating at independentlocations associated with various stages of the ordering, production,transport and delivery of the product.

In accordance with an embodiment, the product is a formulation-basedproduct. In one embodiment, the product is a formulation-based concreteproduct. In other embodiments, the formulation-based product may be anytype of product that is manufactured based on a formulation. Forexample, the formulation-based product may be a chemical compound orother type of chemical-based product, a petroleum-based product, a foodproduct, a pharmaceutical drug, etc. Systems, apparatus and methodsdescribed herein may be used in the production of these and otherformulation-based products.

In another embodiment, statistical information concerning a plurality ofproduction facilities is generated and provided to a producer and/or acustomer. For each of a plurality of production facilities, a series ofactions is performed. For each of a plurality of batches of a concretemixture produced at the respective production facility based on aformulation, a first difference between a measured quantity ofcementitious and a first quantity specified in the formulation isdetermined. A first standard deviation is determined based on the firstdifferences. For each of the plurality of batches, a second differencebetween a measured quantity of water and a second quantity specified inthe formulation is determined. A second standard deviation is determinedbased on the second differences. A first benchmark is selected fromamong the first standard deviations, and a second benchmark is selectedfrom among the second standard deviations. An amount by which costs maybe reduced by improving production at the production facility to meetthe first and second benchmarks is determined.

In accordance with another embodiment, information relating to a changemade to a concrete mixture in a concrete mixer truck is obtained. Forexample, the change may comprise an addition of water to the mixture. Anexpected value of a selected characteristic of the concrete mixture,such as water content, strength, slump, etc., is determined based on thechange. A representation of the expected value is displayed on aprocessing device located in a cab of the concrete mixer truck. Forexample, a difference between the expected value and a design value maybe displayed in the form of a gauge, displayed on a computer carried bythe driver of the truck.

The terms “formulation,” “recipe,” and “design specification” are usedherein interchangeably. Similarly, the terms “components” and“ingredients” are used herein interchangeably.

FIG. 1A illustrates a production management system in accordance with anembodiment. Product management system 10 includes a master databasemodule 11, an input module 12, a sales module 13, an order processing &dispatch module 13A, a production module 14, a transport module 15, asite module 16, an alert module 17 and a purchasing module 18.

Master database module 11 may be implemented using a server computerequipped with a processor, a memory and/or storage, a screen and akeyboard, for example. Modules 12-18 may be implemented by suitablecomputers or other processing devices with screens for displaying andkeep displaying data and keyboards for inputting data to the module.

Master database module 11 maintains one or more product formulationsassociated with respective products. In the illustrative embodiment,formulations are stored in a database; however, in other embodiments,formulations may be stored in another type of data structure. Masterdatabase module 11 also stores other data related to various aspects ofproduction management system 10. For example, master database module maystore information concerning acceptable tolerances for variouscomponents, mixtures, production processes, etc., that may be used insystem 10 to produce various products. Stored tolerance information mayinclude tolerances regarding technical/physical aspects of componentsand processes, and may also include tolerances related to costs. Masterdatabase module 11 may also store cost data for various components andprocesses that may be used in system 10.

Each module 12-16 and 18 transmits data to master database module 11 bycommunication lines 21-26, respectively. Master database module 11transmits data to modules 13, 14, 17 and 18 by communication lines31-34, respectively. Order processing & dispatch module is linked tomaster database module via communication line 22A. Each communicationline 21-26 (including line 22A) and 31-34 may comprise a directcommunication link such as a telephone line, or may be a communicationlink established via a network such as the Internet, or another type ofnetwork such as a wireless network, a wide area network, a local areanetwork, an Ethernet network, etc.

Alert module 17 transmits alerts to the producer and/or customers bycommunication line 35 to site module 16.

Master database module 11 stores data inputted from modules 12-16 and18. Master database module 11 stores data in a memory or storage using asuitable data structure such as a database. In other embodiments, otherdata structures may be used. In some embodiments, master database module11 may store data remotely, for example, in a cloud-based storagenetwork.

Input module 12 transmits to master database module 11 by communicationline 21 data for storage in the form of mixture formulations associatedwith respective mixtures, procedures for making the mixtures, individualingredients or components used to make the mixture, specifics about thecomponents, the theoretical costs for each component, the costsassociated with mixing the components so as to make the product ormixture, the theoretical characteristics of the product, acceptabletolerances for variations in the components used to make the product,the time for making and delivering the product to the site and costsassociated shipping the product.

The terms “product” and “mixture” are used interchangeably herein.

Data transmitted by input module 12 to master database module 11 andstored in master database module 11 may be historical in nature. Suchhistorical data may be used by the sales personnel through sales module13 to make sales of the product.

In one embodiment, sales module 13 receives product data bycommunication line 31 from master database module 11 relating to variousproducts or mixtures that are managed by system 10, the components thatmake up those products/mixtures, the theoretical costs associates withthe components, making the mixture and delivery of the mixture, timesfor delivery of the mixture and theoretical characteristics andperformance specifications of the product. Order processing & dispatchmodule 13A processes orders and handles certain dispatching activities.

Sales module 13 may present all or a portion of the product data to aproducer and/or customer in the form of a menu of options. FIG. 1B showsan exemplary menu 55 that may be presented to a producer and/or customerin accordance with an embodiment. Menu 55 comprises a list of mixturesavailable for purchase, including Mixture A (61), Mixture B (62),Mixture C (63), etc. Each mixture shown in FIG. 1B represents a productoffered for sale. For example, each mixture may be a respective concretemixture that may be purchased by a customer. Menu 55 is illustrativeonly; in other embodiments, a menu may display other information notshown in FIG. 1B. For example, a menu may display the components used ineach respective mixture, the price of each mixture, etc.

From the menu, the producer and/or customer may choose one or moreproducts to purchase. For example, a producer and/or customer maypurchase Mixture A (61) by selecting a Purchase button (71). When theproducer and/or customer selects a mixture (by pressing Purchase button(71), for example), sales module 13 generates an order for the selectedmixture and transmits the order by communication line 22 to masterdatabase module 11. The order may specify the mixture selected by theproducer and/or customer, the components to be used to make the selectedmixture, a specified quantity to be produced, the delivery site, thedelivery date for the product, etc. An order may include other types ofinformation.

In accordance with an embodiment, the producer and/or customer may inputa specialty product into system 10. Such input may be accomplishedthrough input module 12.

Producer and/or customer orders are transmitted to master databasemodule 11. Master database module 11 uses an integrated database systemto manage information relating to the orders, as well as the production,transport, and delivery of the ordered products. FIG. 1C is a flowchartof a method of managing a production system in accordance with anembodiment. At step 81, an order relating to a formulation-based productis received, wherein fulfilling the order requires production of theformulation-based product at a first location, transport of theformulation-based product in a vehicle to a second location differentfrom the first location, and performance of an activity with respect tothe formulation-based product at the second location. As describedabove, the producer's and/or customer's order is transmitted to masterdatabase module 11. Master database module receives the order from salesmodule 13, and stores the order.

Based on the order inputted to master database module 11, masterdatabase module 11 places a production order for production of theproduct to production module 14 by communication line 32. Productionmodule 14 is located at a production facility capable of manufacturingthe purchased product in accordance with the order.

In the illustrative embodiment, the product is a formulation-basedproduct. Thus, the product may be produced based on a formulationdefining a plurality of components and respective quantities for each ofthe components. The formulation may also specify a method, or recipe,for manufacturing the product. The production order provided to theproduction module 14 may include the mixture or product to be made, thecomponents to be used to make the mixture or product, the specificsabout the individual components, the method to make the mixture and thedelivery dates. The product is produced at the production facility andplaced in a vehicle for transport to a delivery site specified in theorder.

At step 83, first information relating to a first change made to theformulation-based product at the first location is received from thefirst location, prior to transport of the formulation-based product. Ifany changes are made to the product at the production facility,production module 14 transmits information relating to such changes tomaster database module 11. For example, a particular component specifiedin the formulation may be replaced by an equivalent component. Inanother example, a quantity of a selected component specified in theformulation may be altered. In another example, an additional componentnot specified in the formulation may be added. For example, componentssuch as water, cementitious, particular chemicals, particular fibers,etc., may be replaced, added, or their specified quantities may bealtered. Master database module 11 receives and stores such information.

At step 85, second information relating to a second change made to theformulation-based product during transport of the formulation-basedproduct is received during transport of the formulation-based product.If any changes are made to the product during transport of the product,transport module 15 transmits information relating to such changes tomaster database module 11. Master database module 11 receives and storessuch information.

Upon arrival at the specified delivery site, the product is delivered.At step 87, third information relating to the activity performed withrespect to the formulation-based product at the second location isreceived from the second location. For example, site module 16 maytransmit to master database module 11 information indicating the time ofdelivery, or information relating to the performance of the productafter delivery.

In the illustrative embodiment, information transmitted among modules11-19, and to a producer and/or customer, may be transmitted in the formof an alert. An alert may be any suitable form of communication. Forexample, an alert may be transmitted as an electronic communication,such as an email, a text message, etc. Alternatively, an alert may betransmitted as an automated voice message, or in another form.

In one embodiment, information is transmitted to master database module11 in real time. For example, strict rules may be applied requiring thatany information concerning changes to a product that is obtained by anymodule (including production module 14, purchase module 18, transportmodule 15, site module 16, etc.) be transmitted to master databasemodule 11 within a predetermined number of milliseconds.

Various embodiments are discussed in further detail below.

As described above, in some embodiments, the product is made at aproduction facility in accordance with a predetermined formulation.Production module 14 operates at the production facility and has storeddata as to the specifics of the individual components or raw ingredientson hand at the facility. FIG. 2 is a flowchart of a method of producinga mixture in accordance with an embodiment. At step 210, an order tomake a product/mixture from specified components is received. Referringto block 220, if the exact components or ingredients are in stock, theproduction facility proceeds to make the mixture/product (step 230). Ifthe production facility does not have on hand the exact componentsneeded to make the mixture/product, then the method proceeds to step 260and determines whether an equivalent component is in stock. If anequivalent component is in stock, the method proceeds to step 270. Atstep 270, production module 14 makes the product using the equivalentcomponent and alerts master database module 11 of the change. Such areplacement may change the cost of the raw materials and/or thecharacteristics of the mixture/product which is finally made.

Returning to block 260, if there is no equivalent component in stock,the production module 14 may send an order by communication line 32 tomaster database module 11 for the specified component (or for theequivalent component). When the order is received, production module 14makes the product (step 240). The manufactured formulation and physicalresults are sent to master database module 11 (step 250).

In another embodiment, production module 14 alerts master databasemodule 11 if the method of manufacture specified in a mixtureformulation is modified. For example, a step of the method may bechanged or eliminated, or a new step may be added. Master databasemodule stores information related to the change. Master database module11 may also determine if the change is within acceptable tolerances andalert the producer and/or customer if it is not within acceptabletolerances. For example, master database module 11 may compare themodified method to stored tolerance information to determine if themodified method is acceptable.

FIG. 3 is a flowchart of a method of handling an order received from aproduction facility in accordance with an embodiment. At step 310, anorder is received from production module 14, by master database module11. At step 320, master database module 11 places an order bycommunication line 34 to purchase module 18 to purchase the neededcomponents or raw materials. Purchase module 18 transmits bycommunication line 26 the specifics of the components that it haspurchased and the estimated delivery date to the production facility aswell as the costs associated with the component. Purchase module 18 isassociated with a raw material/component supply facility. At step 340,master database module 11 receives the specifics on the componentsactually purchased by purchase module 18.

Referring to block 350, if the components purchased (by purchase module18) are the same as the order placed, the method proceeds to step 380,and the product is made and shipped to the production facility. At step382, the recipe produced and the physical results are sent to masterdatabase module 11. At step 384, an alert is sent to master databasemodule 11.

Returning to block 350, if the components purchased (by purchase module18) differ from those specified in the order, the method proceeds toblock 360. Master database module 11 compares the components purchased,either those replaced by the production facility or those purchased bythe purchase module 18, to stored tolerance information (which mayinclude tolerances regarding physical/technical aspects of a componentand/or cost tolerances). Referring to block 360, if the replacementcomponents fall within acceptable tolerances both for performancecharacteristics and cost, then at step 370, the mixture/product is madeis shipped. If the cost or characteristics of the raw ingredients falloutside acceptable tolerances, then the method proceeds to step 380(described above).

FIG. 4 is a flowchart of a method of responding to an alert inaccordance with an embodiment. Specifically, FIG. 4 illustrates a methodof responding to an alert when a production facility replaces an exactingredient with a known equivalent, in accordance with an embodiment. Atstep 410, an alert indicating an equivalent replacement is received bymaster database module 11 from production module 14. Referring to block420, a determination is made by master database module 11 whether theequivalent component is within acceptable tolerances. If the equivalentcomponent is within acceptable tolerances, the method proceeds to step430 and the product is made. Master database module 11 instructsproduction module 14 to proceed with manufacturing the mixture. If theequivalent component is not within acceptable tolerances, the methodproceeds to step 440. At step 440, and an alert is transmitted and theproduct is made. For example, an alert may be transmitted by masterdatabase module 11 or by alert module 17 to the producer and/orcustomer.

At step 450, the variances of actual versus theoretical cost andperformance factors are stored at master database module 11.

As described above, production module 14 receives instructions frommaster database module 11, prior to production of a mixture, specifyingthe recipe and components required for producing the mixture. However,from time to time the batched amounts of each component (i.e., theamount of each component in the batch actually produced) differs fromthe amounts specified in the recipe received from master database module11 due to statistical or control factors.

When quantity variances are outside the specified tolerances, alerts aretransmitted and the actual amounts produced, and cost variances fromtarget costs, are provided to master database module 11. FIG. 5 is aflowchart of a method of responding to an alert indicating a differencebetween a batched quantity and a specified recipe quantity in accordancewith an embodiment. At step 510, an alert is received indicating adifference between a batched quantity and a specified recipe quantity.The alert typically indicates variances of actual versus theoreticalcost and performance factors. Referring to block 520, if the differencesare within acceptable tolerances, the method proceeds to step 530 andthe product is delivered. If the differences are not within acceptabletolerances, the method proceeds to step 540. At step 540, an alert istransmitted and the product is delivered. An alert may be transmitted tothe producer and/or customer, for example. At step 550, the variances ofactual versus theoretical cost and performance factors are stored atmaster database module 11. In other embodiments, variances are notstored.

After production of the mixture, the production facility uses one ormore transport vehicles to transport the product/mixture from theproduction facility to the producer's and/or the customer's site. Suchtransport vehicles may include trucks, automobiles, trains, airplanes,ships, etc. Each transport vehicle is equipped with a transport modulesuch as transport module 15. Transport module 15 transmits bycommunication line 24 to master database 11 information concerning thetransport of the product/mixture. The information concerning thetransport can include changes which are made to the mixture duringtransport (e.g., addition of water or other chemicals), the length oftravel, temperatures during transport, or other events that occur duringtransport. For example, in the ready mix concrete industry it is commonfor a truck transporting the mixture from the production facility to adelivery site to add water and/or chemicals during the transportprocess. Information indicating such addition of chemicals or water istransmitted to master database module 11 by communication line 24.Furthermore, in the ready mix concrete industry, measuring and recordingthe temperature of the concrete during transport is advantageous forseveral reasons: (a) such data can be used to determine a maturity valueper ASTM c1074; (b) such data, in combination with reference heat ofhydration data may be used to determine degree of hydration attainedduring transport; (c) the data, in combination with reference strengthand heat of hydration data may be used to determine pre-placementstrength loss due to pre-hydration prior to discharge of the concrete atproject site.

The transport-related information is transmitted by transport module 15to master database module 11. For example, such information may betransmitted in the form of an alert. The information is analyzed bymaster database module 11 to determine whether the changes that are madeare within acceptable tolerances. FIG. 6 is a flowchart of a method ofmanaging transport-related data in accordance with an embodiment.

At step 610, information indicating changes to a mixture duringtransport is received from a transport module. For example, masterdatabase module 11 may receive an alert from transport module 15indicating that changes occurred to a mixture during transport of themixture. Referring to block 620, a determination is made whether thechanges are within acceptable tolerances. If the changes are withinacceptable tolerances, the method proceeds to step 630. At step 630, theproduct/mixture is delivered to the producer's and/or customer's site.If the changes are not within acceptable tolerances, the method proceedsto step 640. At step 640, an alert is transmitted to the producer and/orcustomer and the product/mixture is delivered. Alerts to the producerand/or customer may be issued by alert module 17, or by master databasemodule 11. At step 650, the variances of actual versus theoreticalrecipe cost and performance factors is stored at master database module11. In other embodiments, the information concerning changes is notstored.

In the illustrative embodiment, the producer's and/or the customer'ssite or location is equipped with site module 16, which transmits tomaster database module 11, by communication line 25, information aboutthe mixture of product that is delivered to the site. Such informationmay include, for example, information indicating the actual performanceof the product/mixture as delivered. Master database module 11 storesthe actual performance data. Master database module 11 may provide tothe producer and/or customer a report concerning various aspects of theactual product delivered.

Site module 16 may also receive alerts from alert module 17 bycommunication line 35.

In the illustrative embodiment, alert module 17 is a module separatefrom master database module 11. However, in other embodiments, thefunctions of alert module 17 may be performed by master database module11.

Alert module 17 may also transmit final reports concerning the productsto site module 16, thereby enabling the seller and the producer and/orcustomer a way of managing the product. Feedback provided throughout theproduction process, as illustrated above, advantageously allows theproducer and/or customer and the manufacturer to manage costs andquality of the products.

The alert functions described above facilitate the process of managingproduction and costs. In response to any alert, the producer and/orcustomer or the manufacturer has the ability to make a decision not tocontinue the production or delivery of the product because the producthas fallen outside of acceptable tolerances.

While the illustrative embodiment of FIG. 1A includes only oneproduction module, one transport module, one site module, one alertmodule, one purchase module, one input module, and one sales module, inother embodiments, a system may include a plurality of productionmodules, a plurality of transport modules, a plurality of site modules,a plurality of alert modules, a plurality of purchase modules, aplurality of input modules, and/or a plurality of sales modules. Forexample, in an illustrative embodiment, suppose that a system used by acompany in the ready mix concrete industry includes a master databasemodule 11 residing and operating on a server computer located inPittsburgh, Pa. The company's sales force may be located in Los Angeles,Calif., where the sales module 13 resides and operates (on a computer).Suppose that a sale is made in Los Angeles, and the purchase orderspecifies a site in San Francisco, Calif. Thus, master database module11 may output an order to a production module 14 which is located at aready mix production facility in the vicinity of San Francisco, Calif.Suppose further that a single production facility in the vicinity of SanFrancisco cannot handle the volume of the concrete that is needed forthe job site in San Francisco. In such a case, master database module 11may output to a plurality of production facilities, each having aproduction module 14, the necessary orders for fulfillment. Thus, thesystem includes a plurality of production modules, one in each of thevarious production facilities. The production facilities produce thespecified mixture and transport the ready mix concrete in a plurality oftrucks to the producer site and/or customer site in San Francisco. Eachtruck has a transport module associated therewith. Suppose that one ormore of the production modules does not have the specific componentsthat were specified in the purchase order for the concrete. Thus,adjustments may be made at the production facility to the concretemixes, and information concerning such adjustments are transmitted backto the master data base module 11. Such adjustment information may beprocessed in accordance with the steps illustrated in FIGS. 3 and/or 4.

During the transport of the ready mix concrete from the variousproduction facilities, the transport modules 15 in each of the truckstransmit to the master database module 11 any changes made to themixture. The master database module 11 may then perform the methoddescribed FIG. 6. In a similar manner, master database module 11 isinformed of any changes occurring during production and, as a result,master database module 11 may perform the method described in FIG. 5.

Finally, the concrete is delivered to the producer and/or customer sitein San Francisco and information concerning the delivered concrete maybe transmitted to the master database module 11. The site module 16 mayalso be used to provide the master database module 11 with informationrelating to one or more of the following: measurements of the actualheat of hydration taken from the fresh state through the hardeningprocess, strength characteristics of the concrete after it is hardened,etc. Advantageously, the feedback provided in this manner to masterdatabase module 11 from the various modules enables the producer and/orcustomer of the concrete in Los Angeles to monitor, on a real timebasis, the concrete poured at the producer's and/or customer'sconstruction site in San Francisco, without having to physically be inSan Francisco.

Furthermore, the producer and/or customer in Los Angeles may monitor, ona real time basis, costs associated with the concrete which is deliveredto the site in San Francisco.

Furthermore, the ready mix concrete producer may associate, in realtime, variances in one or more parameters relating to the concrete'sperformance from specified expectations, and correlate such variances toactual batched versus the expected specified recipe. These capabilitiesadvantageously allow the maintenance of consistent, low standarddeviation production batching from a mixture recipe baseline, andproduction of concrete that has a consistent strength performance with alow standard deviation.

Changes in materials may impact a producer's cost of materials (COM). Anincrease in COM can in turn impact the producer's profitability. In manyinstances, any increase (in percentage terms) in the COM results in amuch greater impact on profitability (in percentage terms). For example,it has been observed that, using ACI 318 statistical quality criteria,it can be demonstrated that each 1% cement or water variance from themix design theoretical recipe value can result in a cost impact ofaround $0.2 to $0.4 per cubic yard. Since such variances can typicallyrange from 2% to 10%, the cost impact may range from $0.4 to $10 percubic yard annually. This cost impact is a very large percentage of theaverage profit of a producer in the ready mix concrete industry, whichis on the order of $1/cubic yard.

Advantageously, the integrated production management system and methoddescribed herein enables a producer to manage the overall productionsystem for ready mix concrete, and allows greater control over changesthat may impact the producer's costs (and profits). The integratedproduction management system and method described herein also provides aproducer and/or customer increased control over the producer's and/orcustomer's construction site.

For convenience, several examples relating to the ready mix concreteindustry are described below.

Concrete Construction & Manufacturing/Production Examples

Examples are provided for three different market segments:

A. Ready Mix Concrete

B. Contractors

C. State Authorities

Closed Loop Solutions (CLS) Overview

Set forth below is a discussion of a closed loop solution (CLS) inaccordance with an embodiment. Each operation has a set of theoreticalgoals and obtained physical or actual results.Practically all operational IT architectures include a collection ofdisparate information systems that need to work together.CLS is an information technology solution that enforces:Data Integrity across linked or associated disparate information systems(Ready Mix Example:Mix costs & formulae to have data integrity or be the same across mixmanagement, sales, dispatch, batch panels, and business systems)Closed Loop Data Integrity, meaning that the operations' goals and itsactual physical results match within tolerances (concrete batch & mixBOMs (Bill of Materials) closely match)

Four Types of CLS for Different Market Segments

I. Ready Mix Producers: Closed Loop Integration (CLI):

-   -   1) CLI has been implemented as a CLS application for many Ready        Mix Producers in the US and Canada.    -   2) CLI applications are real-time, two-way interfaces with        production systems    -   3) One of the main purposes of CLI is to enforce data integrity        between batches in trucks and parent mix designs; CLI closes the        loop between the mix management and production cycles.

II. Ready Mix Producers: Closed Loop Sales Management (CLSM):

-   -   1) CLSM is a CLS application for Ready Mix Producers in the US        and Internationally.    -   2) One of the main purposes of Closed Loop Sales Management is a        project-based workflow for the industry sales process, tracking        actual versus target profitability, This application closes the        loop between actual and target profitability factors. One        benefit is maximization of profitability.

III. Contractors: Closed Loop Quality & Cost:

-   -   1) The solution for the Contractor market segment is similar to        the Closed Loop Quality application, except that it also        includes concrete delivered cost management    -   2) One of the main purposes of Closed Loop Quality & Cost is a        real time enforcement of placed concrete obtained specs and        performance to the applicable project specs, plus monitoring        placed versus as-purchased cost—This application closes the loop        between both the delivered versus specified project concrete        performance and cost.

IV. State Authorities: Closed Loop Quality:

-   -   1) This solution is intended for the Authorities market segment        as a modification of the CLI production driven Ready Mix        application    -   2) One of the main purposes of Closed Loop Quality is a real        time enforcement of placed concrete obtained specs and        performance to the applicable project specs. This application        closes the loop between the delivered versus specified project        concrete performance.

Set forth below are several application examples.

[A] Ready Mix Concrete Producers—CLS Type: Closed Loop Integration forReal Time, Production Level, Consolidated Mix Management

I. Ready Mix Needs Include:

-   -   1) Consolidate critical mix, cost, and quality data in a single        database    -   2) Minimize quality issues    -   3) Utilize materials efficiently    -   4) Real time information visibility—customized by user profile

II. Ready Mix Economics & its Management:

-   -   1) 50% to 70% of cost of business (COB) is cost of materials        (COM)    -   2) A 1% increase in COM can translate to more than a 10%        profitability drop    -   3) Thus, production level materials management is important to        profitability.

TABLE 1 Item per Cyd Net Profit % 5.0% Price $85.00 Cost of Business(COB) $80.75 Net Profit $4.25 Cost of materials (COM) as % of COB 55.0%COM $44.41 1% increase in COM $0.44 Change in COB $0.44 Change in Netprofit ($0.44) % change in net profits per % COM −10.5%

Table 1 shows the relationship between COM and profitability.

III. To Meet Quality, Materials Utilization, and Information VisibilityNeeds:

-   -   1) Optimize mixes to performance and cost goals in a        consolidated database using mix optimization tools.    -   2) Implement closed loop integration (CLI) for the production        level management of optimized mixes; may use alerts application        for alert notification of out-of-tolerance batches.    -   3) Use CLI to ship concrete to mix baselines for implementing        production level, real time cost and quality management. The CLI        system in effect uses mixes as a budgetary tool for both quality        and cost control.

[B] Contractors—CLS Type: Closed Loop Cost & Quality

Table 2 Illustrates Advantages of Real Time, Consolidated Costs andQuality Management.

I. Contractor Concrete Related Needs:

-   -   1) Consolidate aspects of concrete related data across all        projects in a single database.    -   2) Ensure obtained quality meets specifications in order to        minimize quality issues and avoid project delays    -   3) Track & match up contracted volume & cost versus actual        delivered volumes & costs    -   4) Real time information visibility—customized by user profile

II. Basic Contractor Economics:

-   -   1) Concrete cost and quality related schedule delay can amount        to around 16% in profit loss.    -   2) Thus, production level concrete quality and cost management        are important to contractor profitability

III. Closed Loop Solution to Meet Quality, Cost Management, andInformation Visibility Needs:

-   -   1) Implement Closed Loop Cost & Quality (CLCQ) for the real time        management of obtained versus a) specified performance and        recipe factors, b) Actual versus budgeted cost and volume        factors; use an alert system for alert reporting & notification        of out-of-tolerance monitored variables.    -   2) For each project, consolidate quality & engineering team,        tests, concrete deliveries & poured volumes, cost, project mix        designs and specs, project documents, in a single unified        database; do this across all of the contractor's projects in one        or more countries—makes possible sharing and learning cross        project experience    -   3) Use CLCQ to maintain quality, enforce meeting specs in real        time, enforce budgetary cost & volume goals, and create real        time, production level visibility including alerting reports.

Contractor Concrete Economics

-   -   1. 10% to 20% of a project cost is concrete cost; in some        regions/countries this number may be close to 20%    -   2. Since contractor margin is on the order of 1% to 5%, a 1%        change in concrete cost may result on average in about a 8%        profitability drop    -   3. Additionally, it is import to avoid schedule slippage due to        quality issues:        -   1. Each delay day may represent roughly 0.2% to 1% of total            project cost—assume 0.2%        -   2. Each delay day due to concrete quality for a $100 mil            project may cost $200,000, or roughly an 8% drop in            profitability    -   4. Concrete cost and quality schedule delay may total to around        16% in profit loss.    -   5. Thus, production level quality and cost management are        important to contractor profitability, and the related cost        factors can be managed by a closed loop production system

[C] State Authorities—CLS Type: Closed Loop Quality For Real Time,Consolidated Concrete Quality Management

I. State Authority Key Concrete Related Needs:

-   -   1) Consolidate all aspects of concrete related data across all        projects in a single database including mix specifications and        designs, batch data, and test data, as well as the required        QC/QA plan    -   2) Make possible data access, input, and sharing cross projects,        and by project-based entities    -   3) Ensure obtained quality and performance meet specifications        in order to minimize quality issues and avoid project delays    -   4) Track & match up contracted costs & volumes versus actual        values    -   5) Real time information visibility—customized by project & user        profile

II. State Authority Economics—Costs of Poor Quality and ReducedLongevity:

-   -   1) Assume: $100 mil structure; 30,000 m3 concrete @ $100/m3        delivered    -   2) Concrete quality related schedule delay costs may amount to        $70,000/delay day    -   3) Poor quality future repair costs may amount to $120,000 per        1% increase in strength CV    -   4) If the building service life is reduced by one year due to        poor quality, then a revenue loss of around $1.25 mil. may        result    -   5) Thus, production level, real time quality and cost management        is important to the owner economics    -   6) These significant cost factors may be managed by the closed        loop system

III. To Meet Quality, Cost Management, and Information Visibility Needs:

1) For each project, consolidate concrete production volumes, projectmix designs and specifications, and tests in a single database. Also,include the QA/QC plan

-   -   2) Make possible data access, input, and sharing across        projects. Restrict access by project and user profile. Include:        State officials, Engineers/Architects, Contractors, Test Labs,        and Ready Mix Producers    -   3) Implement Closed Loop Quality (CLQ) for the real time        management of obtained versus specified performance and recipe        factors; use an alert system for alert notification of        out-of-tolerance batches. Reconcile tests against QC/QA plan.    -   4) Create real time, production level visibility including        alerting reports.

State Authority Concrete Economics

Assume a $100 mil structure requiring 30,000 m3 concrete (&, an averageof $100/m3 delivered.

-   -   1. Suppose that:        -   1) The owner wishes to amortize the $100 mil cost during a            10-year period, which amounts to a monthly rate of $833,333,            and wishes to lease the building for the same amount        -   2) The owner takes a 30 year mortgage @ 5% interest            amounting to a monthly payment of $535 k.        -   3) This leaves a monthly cash flow of around $300 k, or $3.6            mil/yr    -   2. Poor Quality Cost Factors include:        -   1) Each delay day may result in an opportunity cost of            roughly $70,000, or around 2% of annual cash flow        -   2) If poor quality goes unnoticed, and is repaired at a            later date, each 1% increase in the 28-day strength            coefficient of variation from its ACI 318 design base may            result in future repair costs of $120 k, or around 7% of the            annual cash flow        -   3) If poor quality goes unnoticed, and is not treated, each            one year reduction in the service life may amount to $3.6 in            lost revenues. Annualized over the first 10 years, this            changes the monthly cash flow to around a loss of ($60,000)    -   3. Concrete poor quality costs without a reduction in the        service life can amount to around 9% of cash flow; with service        life reduction, the cash flow can turn negative.    -   4. Thus, production level quality management is important to the        owner economics, and the related cost factors can be managed by        the closed loop system

In accordance with another embodiment, a mixture formulation ismaintained by master database module 11. Localized versions of themixture formulation intended for use at respective production facilitiesare generated, stored, and provided to the respective productionfacilities, as necessary. At a respective production facility, themixture is produced based on the localized version of the mixtureformulation.

FIG. 7A shows a production management system 700 in accordance withanother embodiment. Similar to product management system 10 of FIG. 1A,product management system 700 includes a master database module 11, aninput module 12, a sales module 13, an order processing & dispatchmodule 13A, a production module 14, a transport module 15, a site module16, an alert module 17, and a purchase module 18.

A localization module 19 resides and operates in master database module11. For example, master database module 11 and localization module 19may comprise software that resides and operates on a computer.

Localization module 19 generates one or more localized versions of amixture formulation for use at respective production facilities where amixture may be produced. Localization module 19 may, for example, accessa mixture formulation maintained at master database module 11, analyzeone or more local parameters pertaining to a selected productionfacility, and generate a modified version of the mixture formulation foruse at the selected production facility. Localization module 19 maygenerate localized versions of a particular mixture formulation for oneproduction facility or for a plurality of production facilities. Forexample, master database module 11 may generate localized versions of amixture formulation for every production facility owned or managed by aproducer. Likewise, localization module 19 may generate localizedversions of selected mixture formulations maintained by master databasemodule 11, or may generate localized versions for all mixtureformulations maintained by master database module 11.

FIG. 7B shows a production management system 702 in accordance withanother embodiment. Similar to product management system 10 of FIG. 1A,product management system 702 includes a master database module 11, aninput module 12, a sales module 13, an order processing & dispatchmodule 13A, a production module 14, a transport module 15, a site module16, an alert module 17, and a purchase module 18. In the embodiment ofFIG. 7B, localization module 19 is separate from master database module11 and is connected to master database module 11 by a link 41. Forexample, master database module 11 may reside and operate on a firstcomputer and localization module 19 may reside and operate on a secondcomputer remote from master database module 11. For example,localization module 19 may reside and operate on a second computerlocated at a production facility. Localization module 19 may communicatewith master database module 11 via a network such as the Internet, orvia another type of network, or may communicate via a directcommunication link.

FIG. 7C shows a production management system 703 in accordance withanother embodiment. Product management system 703 includes a masterdatabase module 11, an input module 12, a sales module 13, a productionmodule 14, a transport module 15, a site module 16, an alert module 17,a purchase module 18, and a localization module 19. Modules 11-19 areconnected to a network 775. Modules 11-19 communicate with each othervia network 775. For example, various modules may transmit informationto master database 11 via network 775.

Network 775 may comprise the Internet, for example. In otherembodiments, network 775 may comprise one or more of a number ofdifferent types of networks, such as, for example, an intranet, a localarea network (LAN), a wide area network (WAN), a wireless network, aFibre Channel-based storage area network (SAN), or Ethernet. Othernetworks may be used. Alternatively, network 775 may comprise acombination of different types of networks.

FIG. 8 illustrates a system for the management of localized versions ofa mixture formulation in accordance with an embodiment. In theillustrative embodiment of FIG. 8, master database module 11 compriseslocalization module 19, a mixture database 801, a local factors database802, a components database 803, and a tolerances database 804. A mixtureformulation 810 associated with a particular mixture is maintained inmixture database 801. While only one mixture formulation is shown inFIG. 8, it is to be understood that more than one mixture formulation(each associated with a respective mixture) may be stored by masterdatabase module 11.

Master database module 11 is linked to several production facilities, asshown in FIG. 8. In the illustrative embodiment, master database module11 is in communication with Production Facility A (841), located inLocality A, Production Facility B (842) located in Locality B, andProduction Facility C (843), located in Locality C. While threeproduction facilities (and three localities) are shown in FIG. 8, inother embodiments more or fewer than three production facilities (andmore or fewer than three localities) may be used.

In the embodiment of FIG. 8, local factors database 802 stores localfactor data relating to various production facilities, including, forexample, local availability information, local cost information, localmarket condition information, etc. Localization module 19 may obtainlocal factor data based on the information in local factors database802. Components database stores information pertaining to variouscomponents of product mixtures, such as, for example, technicalinformation concerning various components, costs of various components,etc. Tolerances database 804 stores information defining tolerancesrelated to various components and mixtures.

In the illustrative embodiment, localization module 19 accesses mixtureformulation 810 and generates a localized version for ProductionFacility A (841), shown in FIG. 8 as Mixture Formulation A (810-A).Localization module 19 generates a localized version for ProductionFacility B (842), shown in FIG. 8 as Mixture Formulation B (810-B).Localization module 19 also generates a localized version for ProductionFacility C (843), shown in FIG. 8 as Mixture Formulation C (810-C).Mixture Formulation A (810-A), Mixture Formulation B (810-B), andMixture Formulation C (810-C) are stored at master database module 11.

In order to generate a localized version of a mixture formulation for aparticular production facility, localization module 19 accesses localfactors database 802 and analyzes one or more local factors pertainingto the particular production facility. For example, localization module19 may analyze one or more local availability factors representing localavailability of components in the mixture formulation, one or more localmarket condition factors representing characteristics of the localmarket, one or more local cost factors representing the cost ofobtaining various components in the local market, etc.

Localization module 19 may modify a mixture formulation based on a localfactor. For example, if a local market factor indicates a strongpreference for a product having a particular feature (or a strong biasagainst a certain feature), localization module 19 may alter the mixtureformulation based on such local market conditions. If a particularcomponent is not available in a local market, localization module 19 mayalter the mixture formulation by substituting an equivalent componentthat is locally available. Similarly, if a particular component isprohibitively expensive in a particular locality, localization module 19may reduce the amount of such component in the mixture formulationand/or replace the component with a substitute, equivalent component.

It is to be understood that FIG. 8 is illustrative. In otherembodiments, master database module 11 may include components differentfrom those shown in FIG. 8. Mixtures and local factors may be stored ina different manner than that shown in FIG. 8.

FIG. 9 is a flowchart of a method of generating localized versions of amixture formulation in accordance with an embodiment. The methodpresented in FIG. 9 is discussed with reference to FIG. 10. FIG. 10shows mixture formulation 810 and several corresponding localizedversions of the mixture formulation in accordance with an embodiment.

At step 910, a formulation of a product is stored, the formulationspecifying a plurality of components and respective quantities. Asdiscussed above, mixture formulation 810 is stored at master databasemodule 11. Referring to FIG. 10, mixture formulation 810 specifies thefollowing components and quantities: C-1, Q-1; C-2, Q-2; C-3, Q-3; C-4,Q-4; and C-5, Q-5. Thus, for example, mixture formulation 810 requiresquantity Q-1 of component C-1, quantity Q-2 of component C-2, etc.Mixture formulation 810 may also specify other information, including amethod to be used to manufacture the mixture.

At step 920, a plurality of production facilities capable of producingthe product are identified, each production facility being associatedwith a respective locality. In the illustrative embodiment, localizationmodule 19 identifies Production Facility A (841) in Locality A,Production Facility B (842) in Locality B, and Production Facility C(843) in Locality C.

Referring to block 930, for each respective one of the identifiedproduction facilities, a series of steps is performed. At step 940, alocal factor that is specific to the corresponding locality and thatrelates to a particular one of the plurality of components isidentified. Localization module 19 first accesses local factors database802 and examines local factors relating to Locality A and ProductionFacility A (841). Suppose, for example, that localization module 19determines that in Locality A, component C-1 is not readily available.

At step 950, the formulation is modified, based on the local factor, togenerate a localized version of the formulation for use at therespective production facility. In the illustrative embodiment of FIG.10, localization module 19 substitutes an equivalent component SUB-1 forcomponent C-1 to generate a localized version 810-A of mixture 810.Localized version 810-A is intended for use at Production Facility A(841).

At step 960, the localized version of the formulation is stored inassociation with the formulation. In the illustrative embodiment,localized version 810-A is stored at master database module 11 inassociation with mixture formulation 810.

Referring to FIG. 9, the routine may return to step 930 and repeat steps930, 940, 950, and 960 for another production facility, as necessary.Suppose, for example that localization module 19 determines that inLocality B (associated with Production Facility B (842)), localpurchasers prefer a product with less of component C-2. Localizationmodule 19 thus reduces the quantity of component C-2 in the respectivelocalized version 810-B of mixture 810, as shown in FIG. 10. Inparticular, the amount of component C-2 in localized version 810-B is(0.5)*(Q-2). Localized version 810-B is intended for use at ProductionFacility B (842). Localized version 810-B is stored at master databasemodule 11 in association with mixture formulation 810, as shown in FIG.8.

Suppose that localization module 19 also determines that in Locality C(associated with Production Facility C (843)), local purchasers prefer aproduct with an additional component C-6. Localization module 19 furtherdetermines that component C-6 is an equivalent of component C-5, but isof lower quality. To accommodate local market conditions, localizationmodule 19 reduces the quantity of component C-5 to (0.7)*(C-5) and alsoadds a quantity Q-6 of component C-6 to generate a localized version810-C of mixture 810, as shown in FIG. 10. Localized version 810-C isintended for use at Production Facility C (843). Localized version 810-Cis stored at master database module 11 in association with mixtureformulation 810, as shown in FIG. 8.

Master database module 11 may subsequently transmit one or more of thelocalized versions 810-A, 810-B, 810-C to Production Facilities A, B,and/or C, as necessary. For example, suppose that an order is receivedfor Mixture Formulation 810. Suppose further that Production Facility Aand Production Facility B are selected to produce the mixture. Masterdatabase module 11 accordingly transmits the localized version MixtureFormulation A (810-A) to Production Facility A (841). MixtureFormulation A (810-A) is stored at Production Module 14. Master databasemodule 11 also transmits the localized version Mixture Formulation B(810-B) to Production Facility B (842). Mixture Formulation B (810-B) isstored at a respective production module (not shown) operating atProduction Facility B (842).

The mixture is then produced at each designated production facilitybased on the respective localized version of the mixture formulation. Inthe illustrative embodiment, the mixture is produced at ProductionFacility A (841) in accordance with the localized version MixtureFormulation A (810-A)). The mixture is produced at Production Facility B(842) in accordance with the localized version Mixture Formulation B(810-B).

In accordance with another embodiment, master database module 11 fromtime to time updates the master version of a mixture formulation (storedat master database module 11). Master database module 11 also monitorsversions of the mixture formulation maintained at various productionfacilities. If it is determined that a version of the mixtureformulation stored at a particular production facility is not the sameas the master version of the mixture formulation, an alert is issued andthe local version is synchronized with the master version. For purposesof the discussion set forth below, any version of a mixture formulationthat is stored at master database module 11 may be considered a “masterversion” of the mixture formulation.

In an illustrative embodiment, suppose that master database module 11updates Mixture Formulation 810. This may occur for any of a variety ofreasons. For example, the cost of one of the components in MixtureFormulation 810 may increase substantially, and the particular componentmay be replaced by an equivalent component. Referring to FIG. 11A, theupdated formulation is stored at master database module 11 as UpdatedMixture Formulation 810U.

Master database module 11 also generates localized versions of theupdated mixture formulation. Thus, for example, master database module11 generates an updated localized version of Mixture Formulation 810Ufor Production Facility 841 (in Locality A). The updated localizedversion of is stored at master database module 11 as Updated MixtureFormulation A (810U-A), as shown in FIG. 11A.

Master database module 11 identifies one or more production facilitiesthat store a localized version of Mixture Formulation 810, and notifieseach such production module that Mixture Formulation 810 has beenupdated. If a production module does not have the correct updatedversion of the mixture formulation, the localized version must besynchronized with the updated master version stored at master databasemodule 11. FIG. 12 is a flowchart of a method of synchronizing alocalized version of a mixture formulation with a master version of themixture formulation in accordance with an embodiment.

In the illustrative embodiment, certain aspects of production atProduction Facility A (841) are managed by production module 14. Forexample, production module 14 may operate on a computer or otherprocessing device located on the premises of Production Facility A(841).

At step 1210, a determination is made that a mixture formulation storedat a particular production facility is different from the mixtureformulation stored by the master database module. For example, masterdatabase module may communicate to production module 14 (operating atProduction Facility A (841)) that Mixture Formulation A (810-A) has beenupdated. Production module 14 determines that its current localizedversion of the mixture formulation is not the same as Updated MixtureFormulation A (810U-A).

At step 1220, an alert is transmitted indicating that the version of themixture formulation stored at the particular production facility isdifferent from the mixture formulation stored by master database module11. Accordingly, production module 14 transmits an alert to masterdatabase module 11 indicating that its local version of the mixtureformulation is not the same as the updated version stored at masterdatabase module 11.

At step 1230, the version of the mixture formulation stored at theparticular production facility is synchronized with the mixtureformulation stored at the master database module 11. In response to thealert, master database module 11 provides production module 14 with acopy of Updated Mixture Formulation A (810U-A). Production module 14stores Updated Mixture Formulation A (810U-A), as shown in FIG. 11B.

Various methods and system described above may be used in an integratedclosed-loop production system to manage a production system. Inaccordance with an embodiment, a method of managing a closed-loopproduction system is provided. Master database module 11 provides tosales module 13 descriptions, prices, and other information relating toa plurality of available mixtures, enabling sales module 13 to offerseveral options to potential producers and/or customers. Specifically,master database module 11 provides information relating to a pluralityof concrete mixtures. Sales module 13 may present the information to aproducer and/or customer in the form of a menu, as discussed above withreference to FIG. 1B.

Suppose now that a producer and/or customer considers the availablemixtures and selects one of the plurality of concrete mixtures. Supposefurther that the producer and/or customer submits an order for theselected mixture, specifying parameters such as quantity, date and placeof delivery, etc. For illustrative purposes, suppose that the producerand/or customer selects the mixture associated with mixture formulation810 (shown in FIG. 8) and specifies a delivery site located in or nearLocality A (also shown in FIG. 8). Master database module 11 utilizes aclosed-loop production system such as that illustrated in FIG. 1A tomanage the sale, production and delivery of the selected mixture to theproducer and/or customer.

FIGS. 13A-13B comprise a flowchart of a method of managing a closed-loopproduction system in accordance with an embodiment. At step 1310, anorder for a mixture selected from among the plurality of mixtures isreceived, by a processor, from a sales module operating on a firstdevice different from the processor, the order being associated with apurchase of the mixture by a producer and/or customer. In theillustrative embodiment, sales module 13 transmits the order for theselected concrete mixture to master database module 11. The orderspecifies the selected mixture and other information including quantity,date and place of delivery, etc. Master database module 11 receives theorder for the selected concrete mixture from sales module 13.

At step 1310, a mixture formulation defining a plurality of componentsand respective quantities required to produce the selected mixture isprovided, by the processor, to a production module operating on a seconddevice located at a production facility capable of producing themixture. Accordingly, master database module 11 identifies one or moreproduction facilities capable of producing the selected mixture.Production facilities may be selected based on a variety of factors. Forexample, master database module 11 may select one or more productionfacilities that are located near the delivery site specified in theorder. In the illustrative embodiment, master database module 11 selectsProduction Facility A (841) due to the fact that the producer's and/orcustomer's delivery site is located in or near Locality A. It is to beunderstood that more than one production facility may be selected andused to produce a mixture to meet a particular order.

Master database module 11 transmits Mixture Formulation A (810-A) (orany updated version thereof) to Production Facility A (841). Productionmodule 14 manages and monitors the production process. In theillustrative embodiment, production module 14 determines that aparticular component of mixture formulation A (810-A) is currentlyunavailable and replaces the component with a known equivalent.Production module 14 accordingly transmits an alert to master databasemodule 11 indicating that the component has been replaced. An alert maythen be provided to the producer and/or customer, as well. Production ofthe selected mixture proceeds. In one embodiment, the alert may betransmitted in real time (e.g., within a specified time period afterproduction module 14 receives the information).

At step 1315, first information identifying a modification made to themixture formulation is received, by the processor, from the productionmodule, prior to production of the mixture. Master database module 11receives the alert from production module 14.

At step 1320, an alert is transmitted if the first information does notmeet a first predetermined criterion. If the modification does not meetspecified requirements, master database module 11 transmits an alert tothe producer and/or customer. In one embodiment, the alert istransmitted in real time.

In the illustrative embodiment, a quantity of the mixture actuallyproduced at Production Facility A (841) differs from the quantityspecified in the order. Production module 14 transmits an alert tomaster database module 11 and to alert module 17 indicating that thequantity actually produced differs from the quantity ordered. The alertmay be transmitted in real time. At step 1325, second informationindicating an actual quantity of the mixture produced is received, fromthe production module, prior to delivery of the mixture. Master databasemodule 11 receives the alert and stores the information specifying theactual quantity produced.

At step 1330, an alert is transmitted if the second information does notmeet a second predetermined criterion. If the quantity of concretemixture actually produced does not meet specified requirements, masterdatabase module 11 transmits an alert to the producer and/or customer.In one embodiment, the alert is transmitted in real time.

In another embodiment, production module 14 may inform master databasemodule 11 if the method of manufacture specified in the mixtureformulation is changed. For example, a step of the method may bemodified or eliminated, or a new step may be added.

The method now proceeds to step 1335 of FIG. 13B.

The mixture is now placed on a transport vehicle, such as a truck, andtransported to the delivery site specified in the order. The vehicleincludes transport module 15, which may be a software applicationoperating on a processing device, for example. The vehicle may have oneor more sensors to obtain data such as temperature of the mixture, watercontent of the mixture, etc. During transport, transport module 15monitors the condition of the mixture and detects changes made to themixture.

At step 1335, third information identifying a change made to the mixtureproduced during transport of the mixture is received, from a transportmodule operating on a third device located on a vehicle transporting themixture produced from the production facility to a delivery site. In theillustrative embodiment, the driver of the truck makes a change to themixture during transport to the delivery site. For example, the drivermay add additional water to the mixture while the mixture is in thetruck. Transport module 15 transmits an alert to master database module11 and to alert module 17 indicating the change that was made. In oneembodiment, the alert is transmitted in real time.

At step 1340, an alert is transmitted if the third information does notmeet a third predetermined criterion. If the third information is notwithin pre-established tolerances, an alert is issued to the producerand/or customer. In one embodiment, the alert is transmitted in realtime.

In the illustrative embodiment, the mixture is delivered to theproducer's and/or customer's construction site. At the producer's and/orcustomer's site, site module 16 monitors delivery of the mixture andperformance of the mixture after delivery. At step 1345, fourthinformation relating to delivery of the mixture produced is received,from a site module operating on a fourth device associated with thedelivery site. When the mixture is delivered to the specified deliverysite, site module 16 transmits an alert to master database moduleindicating that the mixture has been delivered. In one embodiment, thealert is transmitted in real time.

At step 1350, an alert is transmitted if it is determined that thefourth information does not meet a fourth predetermined criterion. Forexample, if the delivery of the mixture occurs outside of a specifieddelivery time frame (e.g., if the delivery is late), master databasemodule 11 (or alert module 17) may transmit an alert to the producerand/or customer. In one embodiment, the alert is transmitted in realtime.

The site module 16 may also monitor certain performance parameters ofthe mixture after it is delivered and used. At step 1355, fifthinformation relating to a performance of the mixture is received, fromthe site module. After the mixture is used (e.g., when the concretemixture is laid), site module 16 may transmit to master database module11 information including performance data. In one embodiment, theinformation is transmitted in real time.

At step 1360, an alert is transmitted if it is determined that the fifthinformation does not meet a fifth predetermined criterion. Thus, if theperformance data does not meet specified requirements, master databasemodule 11 (or alert module 17) transmits an alert to the producer and/orcustomer. In one embodiment, the alert is transmitted in real time.

As described above, alerts are issued at various stages of theproduction process to inform master database module 11 of events andproblems that occur during production, transport, and delivery of themixture. Master database module 11 (or alert module 17) may then alertthe producer and/or customer if a parameter does not meet specifiedrequirements.

Master database module 11 may collect information from various modulesinvolved in the production of a mixture, in real time, and provide theinformation to the producer and/or customer, in real time. For example,when master database module 11 receives from a respective moduleinformation pertaining to the production of a mixture, master databasemodule 11 may transmit an alert to the producer and/or customer in theform of an email, or in another format.

In one embodiment, master database module 11 maintains a web pageassociated with a producer's and/or customer's order and allows theproducer (and/or the customer) to access the web page. Informationreceived from various modules involved in the production of the mixturemay be presented on the web page. In addition, information relating tocost analysis may be presented on the web page. For example, an analysisof the impact of a modification to the mixture formulation, a change tothe mixture during production or transport, a delay in delivery, or anyother event, on the cost of materials (COM) and/or on the producer'sprofitability may be provided on the web page.

FIG. 14 shows an exemplary web page that may be maintained in accordancewith an embodiment. For example, access to the web page may be providedto a producer to enable the producer to manage the production system andto control costs and profitability. Web page 1400 includes a customer IDfield 1411 showing the producer's and/or customer's name or otheridentifier, a mixture purchased field 1412 showing the mixture that theproducer and/or customer purchased, a quantity field 1413 showing thequantity of the mixture ordered, and a delivery location field 1414showing the delivery location specified by the producer and/or customer.

Web page 1400 also includes a Production-Related Events field 1420 thatlists events that occur during production of the mixture. Masterdatabase module 11 may display in field 1420 information received fromvarious modules during production of the mixture, including informationindicating modifications made to the mixture formulation prior toproduction, changes made to the mixture during transport of the mixture,information related to delivery, etc. In the illustrative embodiment ofFIG. 14, field 1420 includes a first listing 1421 indicating thatcomponent C-5 of the mixture formulation was replaced by an equivalentcomponent EQU-1 at Production Facility A (prior to production). Field1420 also includes a second listing 1422 indicating that delivery of themixture was completed on Apr. 19, ______.

Web page 1400 also includes a Cost Impact Table 1431 showing theexpected impact of certain events on cost and profitability. Table 1431includes an event column 1441, a cost impact column 1442, and aprofitability impact column 1443. Master database module 11 accessesstored information concerning the costs of various components andcalculates the expected impact of one or more selected events on theproducer's costs. In the illustrative embodiment, row 1451 indicatesthat the replacement of C-5 by EQU-1 is expected to increase the cost ofthe mixture by +2.1%, and reduces the producer's profit by 6.5%.

In accordance with another embodiment, statistical measures of variousaspects of the production process are generated for a plurality ofproduction facilities and used to establish one or more benchmarks.

Concrete performance is generally specified and used on the basis of its28 day compressive strength, or at times for pavement construction onthe basis of its flexure strength at a specified age such as 7 or 28days. The methods of measurement and reporting are generally specifiedby the American Society for Testing and Materials, or ASTM (such as ASTMC39 and C78) and the equivalent International standards such asapplicable EN (European Norms). Additionally, concrete mix design andquality evaluation is guided by American Concrete Institute (ACI) 318 asa recommended procedure, which is almost always mandated by projectspecifications in the US, and also used in many countries worldwide. InACI 318 a set of statistical criteria are established that relateconcrete mix design strength, F'cr, to its structural grade strength,F'c, as used in the design process by the structural engineer. Thus theconcrete producer designs his or her mixtures to meet certain F'crvalues in order to meet certain desired F'c structural grades specifiedin the project specifications. A variable relating F'cr and F'c is thestandard deviation of strength testing, SDT, as determined perprescribed ACI procedures. The ACI formulae include:

For F'c≦5,000 psi:

F'cr=F'c+1.34 SDT  (ACI 1)

(1% probability that the run average of 3 consecutive tests are belowF'c)

F'cr=F'c−500+2.33SDT  (ACI 2)

(1% probability that a single test is 500 psi or more below F'c)

For F'c>5,000 psi—[1] applies but [2] is replaced by [3] below:

F'cr=F'c−0.1F'c+2.33SDT  (ACI 3)

(1% probability that a single test is 10% of F'c or more below F'c)

In general the above equations can be expressed in the following form:

Mix Design Strength (F'cr)=Structural Grade Strength (F'c)+An overdesignfactor proportional to the Standard Deviation of testing, SDT.

The factor SDT is a direct measure of concrete quality and reliability,and experience shows that it can range widely from an excellent level ofon the order of 80 to 200 psi, to the very poor level of over 1,000 psi.Concrete mix design cost factor is directly proportional to SDT, whichmeans that high quality concrete is also less expensive to produce sinceit would contain less cement (or cementitious materials, which includebinders such as slag, fly ash, or silica fume in addition to cement).

Because of the above ACI approach now in practice for many decades, theindustry (including ready mix producers, test labs, contractor, andspecifying engineers) has paid significant attention to test resultsvariability and the standard deviation of testing.

FIG. 15 shows a production management system 1500 in accordance with anembodiment. Product management system 1500 includes a master databasemodule 11, input module 12, sales module 13, production module 14,transport module 15, site module 16, alert module 17, purchase module18, and localization module 19. Production management system 1500 alsoincludes a comparison module 1520, a network 1575 and a cloud database1530. Various components, such as master database module 11, may fromtime to time store data in cloud database 1530. Production managementsystem 1500 also comprises a user device 1540.

In another embodiment, the master database module 11, the comparisonmodule 1520, and the alert module 17 are housed within a single module.

In one embodiment, a batch of a concrete mixture is produced at aproduction facility in accordance with a formulation. Certain aspects ofthe batch produced are measured and differences between the batchproduced and the formulation requirements are identified. Thedifferences are analyzed to determine if the differences fall withinacceptable tolerances.

FIGS. 16A-16B comprise a flowchart of a method of producing andanalyzing a mixture in accordance with an embodiment. At step 1605, amixture formulation is input into a master database module. In theillustrative embodiment, input module 12 provides a formulation for aparticular concrete mixture to master database module 11. Masterdatabase module 11 stores the formulation.

In one embodiment, a plurality of mixture formulations is provided byinput module 12 to master database module 11. A master list of mixtures,comprising a plurality of mixture formulations, is maintained at masterdatabase module 11.

As described above, master database module 11 may generate localizedversions of a mixture formulation. Referring again to FIG. 8,localization module 19 generates localized mixture formulations forProduction Facility A, Production Facility B, etc.

At step 1610, data relating component types and costs are input into themaster database module. Technical data for a variety of components usedin the formulation (and in other formulations), as well as cost data forthe components, is provided by input module 12 to master database module11. Technical data and cost data for various components may be stored ina components database 803, shown in FIG. 8.

At step 1615, first tolerance data and second tolerance data are inputinto the master database module. Input module 12 transmits to masterdatabase module 11 information defining a first tolerance andinformation defining the second tolerance. For example, tolerances mayindicate that an amount of water in a batch of a concrete mixture mustfall within a specified range, or that an amount of cementitious in theconcrete mixture must fall within a specified range. Toleranceinformation is stored in tolerances database 804.

At step 1620, a formulation is provided to the production module. Masterdatabase module 11 transmits the mixture formulation to a selectedproduction facility. For example, master database module 11 may providea respective localized mixture formulation to Production Facility A(841). A different localized mixture formulation may be provided toProduction Facility B (842), for example.

At step 1625, the mixture is produced at the production facility. Theproduction facility produces one or more batches of the mixture. Forexample, Production Facility A (841) may produce a batch of the mixturebased on the mixture formulation.

At step 1630, actual mixture data is provided to master database module.After a batch is made, production module 14 provides batch dataindicating the actual quantity of the mixture produced, the componentsused to make the batch, the quantity of each component, etc., to masterdatabase module 11. Production module 14 obtains batch data indicatingthe actual quantity of the mixture produced, which components wereactually used, etc., and transmits the batch data to master databasemodule 11. Master database module 11 may store the batch data. Themethod now proceeds to step 1635 of FIG. 16B.

At step 1635, the comparison module compares the actual mixture data tothe first tolerance. Comparison module 1520 accesses the stored batchdata, and accesses tolerance information in tolerances database 804(shown in FIG. 8). Comparison module 1520 applies the first tolerance tothe batch data to determine whether the batch data is acceptable.

At step 1640, the comparison module compares the actual mixture data tothe second tolerance. Comparison module 1520 accesses the stored batchdata and applies the second tolerance to the batch data to determinewhether the batch data is acceptable.

Referring to block 1645, a determination is made whether the actualmixture data are within the first tolerance and the second tolerance.Comparison module 1520 determines whether the actual mixture data arewithin the specified tolerances. If the actual mixture data are withinthe first tolerance and the second tolerance, the method proceeds tostep 1660. If the actual mixture data are not within the first toleranceand the second tolerance, the method proceeds to step 1650.

At step 1650, an alert is transmitted to the master database module.Comparison module 1520 transmits to master database module 11 an alertindicating that the batch data are not within acceptable tolerances.

At step 1655, an alert is transmitted to the producer and/or to thecustomer. Alert module 17 transmits to the producer and/or customer analert indicating that the batch data are not within acceptabletolerances.

In another embodiment, a first alert is issued if the batch data is notwithin the first tolerance, and a second alert is issued if the batchdata is not within the second tolerance.

At step 1660, the mixture is delivered to the producer and/or customersite. The mixture is placed on a transport vehicle and is delivered tothe site specified by the producer and/or customer in the order.

In accordance with another embodiment, comparison module 1520 monitorsthe quantity of one or more components in each batch actually produced,and compares the amounts to the amounts of such components as specifiedin the formulation.

FIG. 17 is a flowchart of a method of producing a formulation-basedmixture in accordance with an embodiment. In another illustrativeembodiment, suppose that another producer and/or customer orders adesired quantity of the mixture defined by Mixture Formulation (810).Several production facilities may be selected to produce the mixture,including Production Facility C (841). Master database module 11transmits localized Mixture Formulation C (810-C) to production facilityC (843).

At step 1710, a batch of a mixture is produced based on a formulation. Abatch of the mixture is produced at Production Facility C (843) based onlocalized Mixture Formulation A (810-C). Referring to FIG. 10, localizedMixture Formulation (810-C) specifies the following components andquantities: C-1, Q-1; C-2, Q-2; C-3, Q-3; C-4, Q-4; C-5, (0.7)*(Q-5);and C-6, Q-6.

Referring to block 1720, for each component X in the batch, a series ofstep is performed. Thus, the steps described below are performed withrespect to each of the components C-1, C-2, C-3, C-4, C-5, and C-6. Forconvenience, the method steps are described with respect to componentC-1; however, the steps are also performed for each of the othercomponents.

At step 1730, the actual quantity of the component in the batchedmixture, X_(B), is determined. Thus, the actual quantity of C-1 used inthe batch produced at Production Facility C (843) is determined.Production module 14 obtains this information concerning the actualquantity of the component in the batched mixture, X_(B), and transmitsthe information to master database module 11.

Now a measure of a difference between the batch and the formulation isdetermined based on a relationship between the quantity of the componentin the batched mixture, X_(B), and the quantity of the component asspecified by the formulation, X_(F).

Specifically, at step 1740, a difference between the quantity of thecomponent specified in the formulation and the actual quantity of thecomponent in the batch produced is calculated. Specifically, thedifference (X_(B)−X_(F)) is calculated, where X_(B) is the amount of thecomponent actually used in the batch produced and X_(F) is the amount ofthe component as specified in the formulation. In some embodiments, apercentage value representing the difference may also be computed usingthe following formula:

ΔX=(X _(B) −X _(F))/X _(F).

In the illustrative embodiment, comparison module 1520 calculates thequantity ΔX, and provides the information to master database module 11.The quantity ΔX is stored at master database module 11.

At step 1750, a difference between the cost of the component asspecified in the formulation and the cost of the component in the batchproduced is calculated. Thus, the difference ($X_(B)−$X_(F)) iscalculated, where $X_(B) is the cost of the component actually used inthe batch produced and $X_(F) is the cost of the component as specifiedin the formulation. In some embodiments, a percentage value representingthe difference may also be calculated using the following formula:

Δ$X=($X _(B)−$X _(F))/$X _(F),

In the illustrative embodiment, comparison module 1520 calculates thequantity Δ$X and provides the information to master database module 11.The quantity Δ$X is stored at master database module 11.

In accordance with an embodiment, comparison module 1520 particularlymonitors the quantity of cementitious and the quantity water in eachbatch. Systems and methods for monitoring and analyzing quantities ofcementitious and water in batches produced are described below.

For convenience, the terms CM_(F), CM_(B), W_(F), and W_(B) are definedas follows:

CM_(F)=the amount of cementitious specified in the formulation,

CM_(B)=the actual amount of cementitious in a batch produced,

W_(F)=the amount of water specified in the formulation,

W_(B)=the actual amount of water in a batch produced.

Then ΔCM and ΔW are defined as follows:

ΔCM=CM _(B) −CM _(F)

ΔW=W _(B) −W _(F)

Using the terms defined above, set forth below is a method of computinga standard deviation of ΔCM/CM_(F) (referred to as SDrCM) and a standarddeviation of ΔW/W_(F) (referred to as SDrW, for each productionfacility, across all its production batches and mixes.

In accordance with well-known principles of concrete technology, andsince strength is proportional to CM/W ratio, it can be shown that forany given mix, a variance of the strength S of a given batch of concretehas the following relationship to CM and W:

ΔS/S=(ΔCM/CM)−(ΔW/W)

Accordingly, relative strength increases as CM specified in theformulation increases. Likewise, relative strength increases as Wspecified in the formulation decreases.

In accordance with well-known statistical principles, the variance (VAR)of the strength measure can be expressed as follows:

$\begin{matrix}{{{VAR}\left( {\Delta \; {S/S}} \right)} = {{{VAR}\left( {\Delta \; {{CM}/{CM}}} \right)} + {{VAR}\left( {\Delta \; {W/W}} \right)}}} \\{= {({SDrCM})^{2} + ({SDrW})^{2}}}\end{matrix}\quad$

Now if SDrWCM is the standard deviation of the measured ratio W/CM in abatch actually produced relative to the value of W/CM specified in theformulation, the SDrWCM can be expressed as follows:

(SDrWCM)=[(SDrCM)²+(SDrW)²]^(1/2)

Hence:

SDrS=(SDrWCM),

where SDrS is the standard deviation of relative strength resulting fromthe variability of the batching process. The term “relative strength” asused herein means the difference in strength in all batches actuallyproduced at a given production facility relative to the strengthbaseline specified in the formulation, due to the batching variabilitiesof CM and W, expressed as a ratio with respect to the strength baselinespecified in the formulation.

It follows that:

SD(ΔS)=S×(SDrWCM)

In accordance with an embodiment, the closed loop production managementsystem described herein provides, in real time, to a producer and/or acustomer, the statistical values SDrCM and SDrW, and SD(ΔS). SD(ΔS) is adirect measure of concrete strength performance quality related to thequality of the production batching process, both of which arecharacterized by the applicable SD values. Low batching quality isreflected by a high SD value; high batching quality is reflected by alow SD. Thus as the batching quality deteriorates, the strength qualityalso decreases proportionally.

Accordingly, when the batching quality decreases, it may be necessary toadjust the applicable formulation by using an extra batching drivenincrement in the SDT standard deviation factor. This is done using theACI 318 Eqs. [1]-[3] and the equation above in the following form:

ΔF'cr=1.34×S×(SDrWCM)  [1a]

ΔF'cr=2.33×S×(SDrWCM)  [2a]

ΔF'cr=2.33×S×(SDrWCM)  [3a]

where ΔF'cr is an added mix design strength increment resulting from thebatching variability SDrWCM, for each of the three ACI equations. SinceEquations [2a] and [3a] are identical, the three ACI statisticalcriteria are in fact reduced to two for these batching increment cases.

Because F'cr is the theoretical strength associated with the specifiedformulation, an increase in F'cr is associated with an increase in theCM content at constant W, resulting in an increase in the cost of the CMcost in the mixture. The cost of CM in a mixture can be expressed asfollows:

Φ=CM efficiency factor in PSI/(LB·CYD)

K=CM cost per LB

$CM=CM cost per cyd=(K/Φ)×F'cr

It follows from the equation above and Equations [1a-1b] that:

Δ$CMB=increase in CM cost due to batching SD

Δ$CMB=1.34×(K/Φ)×S×SDrWCM

ΔCSTB=2.33×(K/Φ)×S×SDrWCM

Accordingly, in accordance with an embodiment, standard deviations aredetermined in according with the principles described above, and areused to determine a measure of concrete strength performance quality fora plurality of batches produced at a production facility. FIG. 18 is aflowchart of a method of determining a measure of concrete strengthperformance quality for concrete produced at a production facility inaccordance with an embodiment.

At step 1810, a first difference between a measured quantity ofcementitious and a first quantity specified in a formulation isdetermined, for each of a plurality of batches of concrete produced at aproduction facility. As described above, for each batch, the batched CMis measured, and information indicating the batched CM is provided tomaster database module 11. Comparison module 1520 then determines thedifference ΔCM between the batched CM and the CM amount specified in theformulation.

At step 1820, a first standard deviation is determined based on thefirst differences. In the illustrative embodiment, comparison module1520 calculates the Standard Deviation SDrCM of the difference ofbatched CM versus design specification (formulation) CM over all batchesproduced in the production facility.

At step 1830, a second difference between a measured quantity of waterand a second quantity specified in the formulation is determined foreach of the plurality of batches, where water is the total water addedduring production, transportation, and delivery to the delivery site. Asdescribed above, for each batch, the batched W is measured, andinformation indicating the batched W is provided to master databasemodule 11. Comparison module 1520 determines the difference ΔW betweenthe batched W and the W amount in the formulation.

At step 1840, a second standard deviation is determined based on thesecond differences. Comparison module 1520 calculates the StandardDeviation SDrW of the difference of batched W versus the designspecification (formulation) W over all batches produced in theproduction facility.

At step 1850, a measure of concrete strength performance quality isdetermined for the production facility based on the first standarddeviation and the second standard deviation. In the manner describedabove, comparison module 1520 determines SD(ΔS) based on SDrCM and SDrW.

At step 1860, a measure of a cost of adjusting the formulation isdetermined based on the measure of concrete strength performancequality. Comparison module 1520 calculates the potential impact on costsof adjusting the design specification (formulation). For example, asdescribed above, increasing F'cr may result in an increase in costs dueto an increase in the cost of CM in the mixture. The increase in CM costΔ$CMB may be calculated using equations discussed above.

In accordance with another embodiment, statistical data is provided to aproducer and/or a customer, for example, via a web page displayed on auser device. Suppose, for example, that a producer who owns and/ormanages a plurality of production facilities wishes to compare theperformance of the various production facilities. Statisticalperformance measures of the respective performance facilities areprovided. For example, in the illustrative embodiment of FIG. 15, theproducer may employ user device 1540 to access a web page and view thestatistical data.

FIGS. 19A-19B comprise a flowchart of a method of providing comparativestatistical information relating to a plurality of production facilitiesin accordance with an embodiment. Referring to block 1910, for each of aplurality of production facilities, a series of actions is performed asdescribed below.

For a selected production facility (such as Production Facility A(841)),the following steps are performed. At step 1920, a first standarddeviation of a first difference between a measured quantity ofcementitious and a first quantity specified in a design specification isdetermined. Comparison module 1520 computes the first standard deviationSDrCM of the difference of batched CM versus design specification(formulation) CM over all batches produced in the production facility,as described above in steps 1810-1820.

At step 1930, a second standard deviation of a second difference betweena measured quantity of water and a second quantity specified in thedesign specification is determined. Comparison module 1520 computes thesecond standard deviation SDrW of the difference of batched W versus thedesign specification (formulation) W over all batches produced in theproduction facility, as described above in steps 1830-1840.

At step 1940, a measure of concrete strength performance quality for theproduction facility is determined based on the first standard deviationand the second standard deviation. Comparison module 1520 computesSD(ΔS) based on SDrCM and SDrW, as described above in step 1850.

Referring to block 1950, the method may return to step 1920 andstatistics for another production facility may be generated in a similarmanner. Preferably, statistical information is generated for a pluralityof production facilities. Otherwise, the method proceeds to step 1960 ofFIG. 19B.

At step 1960, information indicating each of the plurality of productionfacilities and, for each respective production facility, thecorresponding first standard deviation, the corresponding secondstandard deviation, and the corresponding measure of concrete strengthperformance quality, is provided in a display. In one embodiment, thestatistical information computed by comparison module 1520 may bedisplayed on a web page such as that shown in FIG. 20. Web page 2001includes a statistics table 2010 which includes six columns 2011, 2012,2013, 2014, 2015, and 2016. Production facility identifier column 2011includes identifiers for a plurality of production facilities. Columns2012, 2013, 2014, and 2015 store values for SDrCM, SDrW, SDrWCM, andSD(ΔS), respectively, for each respective production facility listed.For example, referring to record 2021, the production facilityidentified as PF-1 has the following statistics: sdrcm-1; sdrw-1;sdrwcm-1; sd-1. Column 2016 displays a potential cost savings for eachproduction facility listed.

At step 1970, a first benchmark is selected from among a first pluralityof first standard deviations. For example, in the illustrativeembodiment, comparison module 1520 may determine that the standarddeviation associated with the best performance among those displayed inSDrCM column 2012 is sdrcm-2 (shown in record 2022).

At step 1980, a second benchmark is selected from among a secondplurality of second standard deviations. For example, comparison module1520 may determine that the standard deviation associated with the bestperformance among those displayed in SDrW column 2013 is sdrw-4 (shownin record 2024).

At step 1990, the first benchmark and the second benchmark are indicatedin the display. In the illustrative embodiment, the benchmark standarddeviations are displayed, respectively, in a Benchmark (SDrCM) field2031 and a Benchmark (SDrW) field 2032. The two benchmark values arealso highlighted in columns 2012, 2013. In other embodiments, thebenchmark values may be indicated in a different manner. In anotherembodiment, a benchmark standard deviation of strength (PSI) isdetermined based on the benchmark values from fields 2031, 2032, and/orthe values in column 2014. A benchmark consistency value may bedetermined as well. The benchmark standard deviation of strength valueand benchmark consistency value may be displayed on web page 2001.

At step 1995, a potential cost savings value representing an amount thatmay be saved by improving production at the production facility to thebenchmark is displayed in the display. For example, comparison module1520 determines, for each production facility listed, how much savingsmay be achieved by improving the production process at the facility tomeet the first and second benchmarks. In the illustrative embodiment ofFIG. 20, the cost savings information is displayed in column 2016.

In another embodiment, a single generalized benchmark is determinedbased on the first benchmark and the second benchmark. A potential costsavings value is determined based on the generalized benchmark.

These and other aspects of the present Invention may be more fullyunderstood by the following Examples.

Example Illustration of the Impact of Concrete SD on its CM Cost

As shown in Table 1, concrete variability impacts its CM (cementitiouscost) cost very significantly. The analysis is performed for a concreteof structural grade 4,000 psi, and using the referenced equationspreviously derived in this document. The example analysis assumes a CMefficiency factor, Φ=8 psi/(LB·cyd), and a CM cost, K=$0.045/Lb.Starting at a SD of 200 psi, the SD is increased in 100 psi incrementsin column 2, the mix design strength computed in columns 3 & 4 per twodifferent ACI formulae, with the higher value always governing. The mixCM cost is computed in column 5. The cost of quality variability is wellillustrated in columns 6 & 7; column 6 shows that per each 100 psiincrease in standard deviation of strength, the CM cost will increasebetween $0.75 to $1.31 per cyd. Column 7 shows that the CM cost relativeto very high quality concrete (represented by row 1) can increasedramatically by more than $8/cyd. Noting that the concrete industry onaverage generates a net profit of on the order of $0.5 to $2 per cyd,this example (using realistic numbers) illustrates the tremendousimportance of maintaining low variability.

An important factor for maintaining low strength performance variabilityis the consistency of the batching process.

TABLE 1 Ref# 1 2 3 4 5 6 7 Eng Design Mix Design Relative cost ofStrength Strength: F′cr, psi $CM/CYD $CM Variance Ref# F′c, psi SD, psiEq [1] Eq [2] Eq [9] per 100 psi SD DEL_$CM/cyd 1 4,000 200 4,268 3,966$24.01 $0.00 $0.00 2 4,000 300 4,402 4,199 $24.76 $0.75 $0.75 3 4,000400 4,536 4,432 $25.52 $0.75 $1.51 4 4,000 500 4,670 4,665 $26.27 $0.75$2.26 5 4,000 600 4,804 4,898 $27.55 $1.28 $3.54 6 4,000 700 4,938 5,131$28.86 $1.31 $4.85 7 4,000 800 5,072 5,364 $30.17 $1.31 $6.17 8 4,000900 5,206 5,597 $31.48 $1.31 $7.48 9 4,000 1,000 5,340 5,830 $32.79$1.31 $8.79

Set forth below is a discussion of real-time batch data variability withrespect to mixture design factors (as specified in a formulation, forexample). Hypothetical data are used to illustrate a quantification ofthe cost of strength performance variably as driven by batchingvariability.

Example Quantification of Batching Data Variability

Table 2 sets forth a set of real time data in columns 1-5. Column 6shows the computed standard deviation W/CM using the raw data fromcolumns 3 and 5.

In the example of Table 2, production facility (plant) #141, representedby row 9, is designated as the benchmark production facility (plant)because it shows the least variability.

TABLE 2 Example Quantification of Strength Standard Deviation due toBatching Variability, and the Resulting Cost Ref# 1 2 3 4 5 6 Measuredfrom CLI batch analysis Eq [6] - Del_WATER data [A] & [B] Period Del_CM% FROM MIX % FROM MIX STDEV W/CM Table [1] Volume, [A] [B] [C] Ref #PLANT cyds AVG DELTA SDrCM AVG DELTA SDrW SDrWCM 1 121 5,500 0.10% 0.50%−22.00% 3.60% 3.6% 2 122 3,000 0.11% 0.68% −3.60% 5.40% 5.4% 3 124 6,800−22.30% 8.20% −14.00% 8.00% 11.5% 4 128 2,000 0.85% 1.58% −10.00% 4.50%4.8% 5 131 8,990 −0.49% 0.33% −13.70% 6.00% 6.0% 6 135 6,000 −0.33%0.59% −7.40% 2.10% 2.2% 7 138 2,500 −0.08% 0.56% −11.00% 5.30% 5.3% 8140 9,850 −0.33% 0.40% −8.70% 11.60% 11.6% 9 141 6,780 −0.16% 0.70%−12.40% 2.00% 2.1% 10 142 4,560 −0.09% 0.23% −9.60% 3.60% 3.6% 11 1437,860 0.34% 0.71% −20.20% 6.00% 6.0% 12 146 3,450 1.26% 4.08% −13.80%6.60% 7.8% 13 147 5,450 2.20% 1.82% −14.60% 2.10% 2.8% 14 150 9,5400.41% 1.71% −11.00% 9.20% 9.4%

Assuming an average concrete mix design strength of 4,000 psi, Table 3shows the strength SD (Column 3) computed from the SD of W/Cm; thestrength SD varies by more than a factor of 5 from 85 psi for thebenchmark plant to 458 psi in plant #124 (row 3). If this batchingstrength SD were reduced to the benchmark value, then significant CMcosts would be saved as shown in column 4; this cost factor varies from$0.02 per cyd to $2.85 due to the varying batching qualities of theproduction facilities.

Supposing that the mix designs (formulations) developed for thebenchmark plant (production facility) are used across all the productionfacilities, this could lead to a very costly situation, sinceprobability analysis shows that for each 100 psi increase in strength SDfrom its assumed mix design value, the failure rate will increase bymore than 4%, which translates to a potential remedial cost of around$2/cyd per 100 psi of SD increase.

TABLE 3 Closed Loop W/CM Ratio & Batching Strength Standard DeviationsFrom Real Time Data 3 4 2 Computed from batch data for Computed avgstrength of 4,000 psi per Table [1] Batching 1 STDEV Strength Bench Ref#Period W/CM SD [D] Mark Table [2] Volume, [C] SD Savings Ref # PLANTcyds SDrWCM (Del_S) [E] 1 121 5,500 3.6% 145 $0.45 2 122 3,000 5.4% 218$1.00 3 124 6,800 11.5% 458 $2.80 4 128 2,000 4.8% 191 $0.80 5 131 8,9906.0% 240 $1.17 6 135 6,000 2.2% 87 $0.02 7 138 2,500 5.3% 213 $0.96 8140 9,850 11.6% 464 $2.85 9 141 6,780 2.1% 85 $0.00 10 142 4,560 3.6%144 $0.45 11 143 7,860 6.0% 242 $1.18 12 146 3,450 7.8% 310 $1.69 13 1475,450 2.8% 111 $0.20 14 150 9,540 9.4% 374 $2.17 AVG/YCD $1.21

In accordance with another embodiment, information relating to acharacteristic of a mixture carried in a vehicle is provided to thedriver of the vehicle. For example, if water is added to a concretemixture carried in a vehicle, information indicating how the added waterimpacts the concrete's water content, strength, slump, etc., is providedto the driver. Such information is displayed, for example, on a screenof a laptop computer (or other processing device) held by the driver.

In current concrete production and delivery systems, water is added to aconcrete mixture at various stages of production and delivery. Inparticular, water may be added to a concrete mixture being carried in amixer truck at various stages as described below.

At the production facility, most of the quantity of water specified inthe formulation is added; however, a certain amount (usually between 10%and 20%) is held back to allow for in-truck additions of water. Thisquantity of water that is held back is referred to as trim water. Thetrim amount is typically 1 to 5 gal/cyd, with the mix design waterranging on average from 30 to 40 gal/cyd. After the truck is under thebatch plant hopper at the production facility, the truck is driven underan apparatus referred to as a slump rack. At this stage, the driver, bywatching the drum rotation hydraulic pressure gauge, and observing itvisually, adds enough water to bring the batch up to a slump value underthe specified formulation slump value. The driver leaves the slump valuebelow the formulation value to allow for in-truck additions of water.The driver typically adds the remaining water to the mixture while themixture is being transported, to bring the slump up to the formulationvalue.

In accordance with an embodiment, an alert is transmitted to masterdatabase module 11 to report each addition of water at the productionfacility, and an alert is transmitted to master database module 11 toreport each addition of water during transport. Master database module11 stores the data received in each alert.

Disadvantageously, the manual measuring and adjusting of water contentrequired by current concrete production and delivery systems asdescribed above is prone to human error and therefore can be unreliable.This unreliability is a significant source of concrete variance and itsassociated cost. Water quantity variability is a main source of concreteW/CM ratio variance, which in turn results in strength variance. Forexample, a 10% StDev of W/CM of batched values versus formulationvalues, for a 5,000 psi concrete mixture directly results in a strengthStDev 500 psi, which in turn can be shown to increase the concrete costby 3% to 5%. Disadvantageously, such variability can have a negativeimpact on a producer's profitability.

FIG. 21 shows a production and delivery management system in accordancewith an embodiment. Similar to certain embodiments described above,product management system 2100 includes a master database module 11, aninput module 12, a sales module 13, an order & dispatch module 13A, aproduction module 14, a transport module 15, a site module 16, an alertmodule 17, a purchase module 18, and a localization module 19.Production management system 2100 also includes a user device 2106. Userdevice 2106 communicates with master database module 11 via connection2104, which may include, for example, a wireless connection via awireless network and/or a connection via the Internet.

FIG. 22 shows a concrete mixer truck 2210 carrying a concrete mixture2235 in a mixer 2220. Mixture 2235 is a concrete mixture prepared basedon a formulation. Truck 2210 includes transport module 15. Transportmodule 15 obtains information relating to truck 2210, such as itslocation, and information relating to mixture 2235, such as informationindicating any additions of water and/or chemicals made to mixture 2235during transport, and transmits such information to master databasemodule 11. Transport module 15 may comprise a processing device havingwireless communication capabilities, for example. For example, transportmodule 15 may communicate with master database module 11 via connection24, which may be a connection over a wireless network and/or anothernetwork such as the Internet.

A driver 2103 located in a cab 2215 of truck 2210 holds user device2106. In accordance with an embodiment, the driver may receive, via userdevice 2106, information relating to mixture 2235.

In one embodiment, real-time communication between user device 2106 andmaster database module 11 is achieved via the GPS data stream of vehicle2210.

FIG. 23 shows components of user device 2106. User device 2106 comprisesa processor 2301, a memory 2302, a storage 2303, a network interface2304, one or more input/output devices 2305, a transceiver 2312, anantenna 2314, and a display 2320. Processor 2301 orchestrates theoperations of one or more components of user device 2106. Memory 2302and storage 2303 are used by other components of user device 2106 tostore various types of data. Network interface 2304 enables user device2106 to communicate via a network such as the Internet, a wirelesscommunication network, or another type of network. Input/output devices2305 allow a user to provide data to, and receive information from, userdevice 2106. Input/output devices 2305 may include, for example, akeyboard, a computer mouse, a microphone, etc. Antenna 2314 receivesvarious types of signals propagating via electromagnetic waves.Transceiver 2312 transmits and receives signals via antenna 2314.

User device 2106 may be any suitable type of processing device. Forexample, user device 2106 may be a personal computer, a laptop computer,a tablet device, a wireless telephone, a personal digital assistant, amedia player, a processing device built into the dashboard of a vehicle,etc.

In accordance with an embodiment, a real-time gauge is displayed on userdevice 2106 for the purpose of tracking and displaying the impact of anyadditions of water and/or chemicals on the mixture 2235 in truck 2210.The impact of any addition of water and/or chemicals on one of a varietyof characteristics of the mixture may be displayed on the gauge as adifference from a respective formulation value. For example, when wateris added to the mixture, the addition is recorded by master databasemodule 11. Master database module 11 then determines the expected impactof the added water on the water content of the mixture, on concretestrength, on slump, and/or on other characteristics of the mixture. Forexample, the expected impact may be computed relative to the designvalue (the theoretical value computed based on the formulation) of watercontent, strength, slump, etc. The expected impact may be displayed inthe form of an indicator on a gauge shown on user device 2106; the gaugemay also display acceptable tolerances and whether the expected value ofa particular characteristic after the addition is within the specifiedtolerances. In the illustrative embodiment, the driver of truck 2210carries user device 2106 in the cab of the truck, to monitor the statusof the mixture.

FIG. 24 is a flowchart of a method of providing information relating toa mixture carried in a vehicle to the driver of the vehicle inaccordance with an embodiment. Referring to the illustrative embodimentsof FIGS. 21 and 22, suppose that truck 2210 obtains mixture 2235 at aproduction facility. As the truck pulls under the production facility(no water has yet been added), master database module 11 provides touser device 2106 a web page or an App display such as that shown in FIG.25. Web page 2500 (or an App display) includes a gauge 2510 showing thequantity of water in the mixture, represented as the difference betweenthe expected quantity of water in the mixture and the design quantitydetermined based on the formulation. Gauge 2510 comprises a plurality ofmarkings 2540 representing possible values (e.g., −2 gal/cyd, +2gal/cyd, etc.) for the difference between the expected quantity and thedesign quantity. The difference is indicated by an arrow 2523. Gauge2510 also displays a shaded region 2536 representing a range ofacceptable tolerances for the quantity of water in the mixture. Thus, inthe illustrative embodiment, the acceptable tolerances for water includequantities between −1 gal/cyd relative to the design quantity and +1gal/cyd relative to the design quantity. Master database module 11 maycause user device 2106 to display web page 2500 (or an App display) ondisplay 2320 (shown in FIG. 23), for example.

Before any water is added, arrow 2523 indicates a difference of zero(0), as shown in FIG. 25.

In the illustrative embodiment, water is added to mixture 2235 at theproduction facility; however, the trim amount is 3 gal/cyd; this amountis not added to the mixture, as is common practice in the concreteindustry. Production module 14 communicates to master database module 11the amount of water added and the trim amount. Master database module 11stores the information.

Master database module 11 again determines an expected quantity of waterin the mixture, based on the addition of water (without the trim).Master database module 11 also determines a theoretical (design)quantity that the mixture should have at this stage in production, basedon the formulation. Referring to FIG. 26, arrow 2523 now indicates −3gal/cyd, due to the 3 gal/cyd of trim water that was held back.Accordingly, the driver may add up to 4 gal/cyd of water duringtransport and still be within acceptable tolerances.

Truck 2220 now begins to transport the mixture to a specified deliverysite. Production module 14 (operating at the production facility)transmits an alert to master database module 11 that the truck has leftthe facility and is en route to the delivery site. Master databasemodule 11 receives the information concerning the status of truck 2220and stores the information.

During transport, the driver may add water to the mixture, as is commonpractice in the concrete industry. As discussed above, in theillustrative embodiment, the driver may add up to 4 gal/cyd of water tomixture 2235 during transport and still be within acceptable tolerances.When water is added during transport, transport module 15 detects theaddition of water and transmits an alert to master database module 11indicating how much water was added. Referring to FIG. 24, at step 2410,a change made to a mixture during transport of the mixture in a vehicleis determined, wherein the mixture is associated with a formulation.Supposing that the driver adds 2.5 gal/cyd during transport, masterdatabase module 11 receives the information from transport module 15concerning the addition of water and stores the information.

At step 2420, an expected measure of a characteristic of the mixture isdetermined based on the change. Master database module 11 examines theaddition of water made to mixture 2235 during transport, and examinesprevious additions of water to the mixture, and determines an expectedquantity of water for mixture 2235. Master database module 11 mayconsider historical data concerning other, prior mixtures in determiningan expected quantity of water for mixture 2235. For example, masterdatabase module 11 may also consider factors such as type ofcementitious temperature, distance traveled, etc. to determine anexpected quantity of water.

At step 2430, a desired measure of the characteristic is determinedbased on the formulation. Master database module 11 examines theformulation from which mixture 2235 was made and determines atheoretical (design) quantity of water that the mixture should contain.

At step 2440, a difference value representing a difference between theexpected measure and the desired measure is determined. Master databasemodule 11 computes a difference between the theoretical (design)quantity of water formulation determined using the formulation and theexpected quantity of water. At step 2450, the difference value istransmitted to a communication device disposed in the vehicle. Masterdatabase module 11 transmits to user device 2106 information indicatingthe difference between the design quantity and the expected quantity ofwater. At step 2460, master database module 11 causes the communicationdevice to display the difference value. Master database module 11presents a web page (or App display) showing the difference value on agauge. Returning to the illustrative embodiment described above, afterthe driver adds 2.5 gal/cyd of water during transport, master databasemodule 11 causes gauge 2510 to appear as shown in FIG. 27. Gauge 2510now indicates that the expected quantity of water relative to the designquantity is approximately −0.5, which is within shaded region 2536 andtherefore within acceptable tolerances.

The systems and methods for providing information to the driver of atruck transporting a mixture, as described herein, advantageouslyempowers the driver with a real-time, quantitative management tool. Inaddition, the systems and methods described herein facilitateoperational management transparency in real-time across a large numberof trucks.

While in the illustrative embodiment described above, the methoddescribed in FIG. 24 is used to determine and display informationconcerning the impact of a change in the quantity of water on theexpected quantity of water in a mixture, in other embodiments, similarmethods may be used to determine the impact of a change made to amixture on other characteristics, including, without limitation, astrength of the mixture, a slump of the mixture, a standard deviation ofstrength, a standard deviation of slump, a quantity of cementitious inthe mixture, a cost measure associated with the mixture, etc.

For example, in accordance with another embodiment, master databasemodule 11 determines the impact of an addition of a quantity of water toa concrete mixture carried in vehicle 2210 on the expected strength ofthe concrete mixture. Master database module 11 causes user device 2106to display a difference between the expected strength value and atheoretical (design) strength value determined based on the formulation.Using associated strength test data with the given formulation, andreal-time regression of such data using Abrams' W/CM law and utilizationof actual W and CM values, master database module 11 computes theinfluence of the added quantity of water (delta_water) on the strengthof the mixture. The difference between expected strength and designstrength may be displayed on a web page (or App display) such as thatshown in FIG. 28. Web page 2800 includes a gauge 2810 that comprises aplurality of markings 2830 representing possible differences betweenexpected strength and design strength. The sensitivity may be, forexample, on the order of 100 psi to more than 200 psi per 1 gal/cyd ofwater depending on the strength grade of formulation. Gauge 2810includes an arrow 2816 that indicates the difference. Gauge 2810 alsoincludes a shaded region 2804 representing a region of acceptabletolerances.

Thus, for example, if the driver holds back 1 gal/cyd of water and thedesign strength is 4,000 psi, the gauge will show around +150 psi,indicating that the expected average strength will be around 4,150 psi.In the illustrative embodiment of FIG. 28, arrow 2816 indicates that thedifference between expected strength and design strength isapproximately +150 psi.

In another embodiment, a gauge showing strength StDev for a givenformulation from data stored in a master database, calculated based onhistorical data, may be displayed.

In accordance with another embodiment, master database module 11determines the impact of an addition of a quantity of water to aconcrete mixture carried in vehicle 2210 on the expected slump of theconcrete mixture. Master database module 11 causes user device 2106 todisplay a difference between the expected slump value and a theoretical(design) slump value determined based on the formulation. Usingassociated slump test data with the given formulation, and real-timeregression of such data, master database module 11 computes theinfluence of the added quantity of water (delta_water) on the slump ofthe mixture. The difference between expected slump and design slump maybe displayed on a web page (or App display) such as that shown in FIG.29. Web page 2900 includes a gauge 2910 that comprises a plurality ofmarkings 2930 representing possible differences between expected slumpand design slump. The sensitivity may be, for example, on the order of 1inch to 2 inches slump per gal/cyd of added water. Gauge 2910 includesan arrow 2916 that indicates the difference. Gauge 2910 also includes ashaded region 2904 representing a region of acceptable tolerances.

In an illustrative embodiment, supposing the formulation design slump is4 inches, and the driver holds back 1 gal/cyd of water, gauge 2910 mayshow between −1 inch and −2 inches, as shown in FIG. 29.

In accordance with an embodiment, the effect of the slump retention ratecan be determined using the principles set forth below. It is noted thatcurrent technology in concrete mixer trucks typically includesfunctionality for measuring and wirelessly transmitting data indicatingthe temperature inside the truck's drum.

The rate of slump loss is a function of both temperature T (in degreesabsolute) and time t, determined using the algorithm described below.

-   -   1. SLP (t,T)=(SLP_(initial))(Exp[(−a)(t/T)]), where SLP=slump,        SLP_(initial)=slump when batched, and “a” is an        experimentally/empirically determined constant. SLP_(initial)        may be estimated based on methods described above.    -   2. The function described in (1) above is used to compute SLUMP        retention during transport and delivery. Accordingly, the slump        gauge continually auto-updates every few minutes. For example,        if the gauge indicates a delta-slump of zero at the production        facility, at a location half-way to the delivery site, the gauge        may show −2 inches.    -   3. When water is added incrementally, the computation is        readjusted for each new incremental addition of water, and        superimposed on the previously existing retention profiles.    -   4. Thus, the slump gauge may show decreased slump over time,        where the decrease may be higher when the temperature is higher.    -   5. However, when water is added, there is a discrete slump        increase followed by a time and temperature dependent decline.

In another embodiment, a gauge showing StDev of slump for a givenformulation from data stored in a master database, calculated based onhistorical data, may be displayed.

FIG. 30 is a flowchart of a method of providing information relating toa concrete mixture in accordance with an embodiment. At step 3010,information relating to a change made to a concrete mixture in aconcrete mixer truck is obtained. At step 3020, an expected value of aselected characteristic of the concrete mixture is determined based onthe change. At step 3030, the expected value is displayed on aprocessing device located in a cab of the concrete mixer truck.

In accordance with another embodiment, master database module 11determines an impact of an addition of a particular component to amixture, on a characteristic of the mixture. The component may be water,a chemical, or any other component of the mixture. For example, anexpected value of a selected characteristic of a concrete mixture may bedetermined based on an added quantity of a chemical. A differencebetween the expected value and a design (formulation) value for thecharacteristic is determined, and the difference is displayed to thedriver of the transport vehicle, in the form of a gauge.

The impact of chemicals may be more complicated than that of water.Thus, methods and systems similar to those described above may be used;however, the test data used to drive the gauge algorithms may be basedon tests performed on concrete mixtures including the particularchemicals of interest.

In another embodiment, a gauge such as any of those shown in FIGS. 25-29may be color coded to assist the driver in comprehending the effect thatany addition of water (or other component) may have on the mixture. Forexample, referring to gauge 2510 shown in FIGS. 25-27, a left-handportion of shaded region 2536 may be colored green, indicating that anyadditions of water to the concrete mixture made while arrow 2523 is inthis (green) zone have a positive effect on the concrete's strength; aright-hand portion of shaded region 2536 may be colored red, indicatingthat additions of water while arrow 2523 is in this (red) region have anegative effect on the concrete's strength. Other regions of a gauge maybe colored differently to convey other information.

In another embodiment, a user or operations manager may optionallyswitch a gauge between an analog mode (shown in the figures) to adigital mode, in which delta and limit values are shown digitally. Datashown in digital form may be color-coded as appropriate.

In another embodiment, a gauge may be switched to SI units or topercentage values.

The methods and systems described herein are not to be construed aslimiting. While these methods and systems are described as being used todisplay information relating to water content, strength, slump, etc., inother embodiments, a gauge showing other characteristics of a mixturemay be provided and displayed on user device 2106.

In accordance with another embodiment, a combined gauge displayingmultiple characteristics, e.g., data related to water in mixture 2235,data related to the slump of mixture 2235, and data related to thestrength of mixture 2235, may be displayed on user device 2106. FIG. 31shows a web page displaying a combined gauge showing water data, slumpdata, and strength data in accordance with an embodiment. Gauge 3110includes a first region 3114 in which a first arrow 3125 indicates adifference in expected slump of mixture 2235 relative to design slump.Gauge 3110 includes a second region 3112 in which a second arrow 3123indicates a difference in water in mixture 2235 relative to a designquantity of water. Gauge 3110 includes a third region 3116 in which athird arrow 3121 indicates a difference in the strength of mixture 2235relative to design strength.

In another embodiment, some or all of the functions described herein asbeing performed by master database module 11 with respect to determiningdata to be displayed on a gauge, and causing a user device to displaythe gauge, are performed by user device 2106. Thus, for example, userdevice 2106 (located in the cab of truck 2210) may obtain informationrelating to a change made to a concrete mixture located in the truck,determine an expected value of a selected characteristic of the concretemixture based on the change, determine a difference between the expectedvalue and a design value, and display the difference value on a displaysuch as display 2320 (shown in FIG. 23). User device 2106 may displaysuch information in the form of a gauge.

In certain embodiments, communications between master database module11, user device 2106, and other components are conducted in real time.Thus, data relating to changes made in components of mixture 2235 arecommunicated to master database module 11 in accordance withpredetermined time constraints. Similarly, data relating to expectedquantities of water, expected strength, expected slump, etc., anddifference values, are transmitted by master database module 11 to userdevice 2106 in accordance with predetermined time constraints.

In various embodiments, the method steps described herein, including themethod steps described in FIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B, 16A-16B,17, 18, 19A-19B, 24, and/or 30, may be performed in an order differentfrom the particular order described or shown. In other embodiments,other steps may be provided, or steps may be eliminated, from thedescribed methods.

Systems, apparatus, and methods described herein may be implementedusing digital circuitry, or using one or more computers using well-knowncomputer processors, memory units, storage devices, computer software,and other components. Typically, a computer includes a processor forexecuting instructions and one or more memories for storing instructionsand data. A computer may also include, or be coupled to, one or moremass storage devices, such as one or more magnetic disks, internal harddisks and removable disks, magneto-optical disks, optical disks, etc.

Systems, apparatus, and methods described herein may be implementedusing computers operating in a client-server relationship. Typically, insuch a system, the client computers are located remotely from the servercomputer and interact via a network. The client-server relationship maybe defined and controlled by computer programs running on the respectiveclient and server computers.

Systems, apparatus, and methods described herein may be used within anetwork-based cloud computing system. In such a network-based cloudcomputing system, a server or another processor that is connected to anetwork communicates with one or more client computers via a network. Aclient computer may communicate with the server via a network browserapplication residing and operating on the client computer, for example.A client computer may store data on the server and access the data viathe network. A client computer may transmit requests for data, orrequests for online services, to the server via the network. The servermay perform requested services and provide data to the clientcomputer(s). The server may also transmit data adapted to cause a clientcomputer to perform a specified function, e.g., to perform acalculation, to display specified data on a screen, etc.

Systems, apparatus, and methods described herein may be implementedusing a computer program product tangibly embodied in an informationcarrier, e.g., in a non-transitory machine-readable storage device, forexecution by a programmable processor; and the method steps describedherein, including one or more of the steps of FIGS. 2, 3, 4, 5, 6, 9,12, 13A-13B, 16A-16B, 17, 18, 19A-19B, 24 and/or 30, may be implementedusing one or more computer programs that are executable by such aprocessor. A computer program is a set of computer program instructionsthat can be used, directly or indirectly, in a computer to perform acertain activity or bring about a certain result. A computer program canbe written in any form of programming language, including compiled orinterpreted languages, and it can be deployed in any form, including asa stand-alone program or as a module, component, subroutine, or otherunit suitable for use in a computing environment.

A high-level block diagram of an exemplary computer that may be used toimplement systems, apparatus and methods described herein is illustratedin FIG. 32. Computer 3200 includes a processor 3201 operatively coupledto a data storage device 3202 and a memory 3203. Processor 3201 controlsthe overall operation of computer 3200 by executing computer programinstructions that define such operations. The computer programinstructions may be stored in data storage device 3202, or othercomputer readable medium, and loaded into memory 3203 when execution ofthe computer program instructions is desired. Thus, the method steps ofFIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B, 16A-16B, 17, 18, 19A-19B, 24 and/or30 can be defined by the computer program instructions stored in memory3203 and/or data storage device 3202 and controlled by the processor3201 executing the computer program instructions. For example, thecomputer program instructions can be implemented as computer executablecode programmed by one skilled in the art to perform an algorithmdefined by the method steps of FIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B,16A-16B, 17, 18, 19A-19B, 24 and/or 30. Accordingly, by executing thecomputer program instructions, the processor 3201 executes an algorithmdefined by the method steps of FIGS. 2, 3, 4, 5, 6, 9, 12, 13A-13B,16A-16B, 17, 18, 19A-19B, 24 and/or 30. Computer 3200 also includes oneor more network interfaces 3204 for communicating with other devices viaa network. Computer 3200 also includes one or more input/output devices3205 that enable user interaction with computer 3200 (e.g., display,keyboard, mouse, speakers, buttons, etc.).

Processor 3201 may include both general and special purposemicroprocessors, and may be the sole processor or one of multipleprocessors of computer 3200. Processor 3201 may include one or morecentral processing units (CPUs), for example. Processor 3201, datastorage device 3202, and/or memory 3203 may include, be supplemented by,or incorporated in, one or more application-specific integrated circuits(ASICs) and/or one or more field programmable gate arrays (FPGAs).

Data storage device 3202 and memory 3203 each include a tangiblenon-transitory computer readable storage medium. Data storage device3202, and memory 3203, may each include high-speed random access memory,such as dynamic random access memory (DRAM), static random access memory(SRAM), double data rate synchronous dynamic random access memory (DDRRAM), or other random access solid state memory devices, and may includenon-volatile memory, such as one or more magnetic disk storage devicessuch as internal hard disks and removable disks, magneto-optical diskstorage devices, optical disk storage devices, flash memory devices,semiconductor memory devices, such as erasable programmable read-onlymemory (EPROM), electrically erasable programmable read-only memory(EEPROM), compact disc read-only memory (CD-ROM), digital versatile discread-only memory (DVD-ROM) disks, or other non-volatile solid statestorage devices.

Input/output devices 3205 may include peripherals, such as a printer,scanner, display screen, etc. For example, input/output devices 3205 mayinclude a display device such as a cathode ray tube (CRT) or liquidcrystal display (LCD) monitor for displaying information to the user, akeyboard, and a pointing device such as a mouse or a trackball by whichthe user can provide input to computer 3200.

Any or all of the systems and apparatus discussed herein, includingmaster database module 11, input module 12, sales module 13, productionmodule 14, transport module 15, site module 16, alert module 17,purchase module 18, localization module 19, comparison module 1520,cloud database 1530, user device 1540, and user device 2106, andcomponents thereof, including mixture database 801 and local factorsdatabase 802, for example, may be implemented using a computer such ascomputer 3200.

One skilled in the art will recognize that an implementation of anactual computer or computer system may have other structures and maycontain other components as well, and that FIG. 32 is a high levelrepresentation of some of the components of such a computer forillustrative purposes.

The foregoing Detailed Description is to be understood as being in everyrespect illustrative and exemplary, but not restrictive, and the scopeof the invention disclosed herein is not to be determined from theDetailed Description, but rather from the claims as interpretedaccording to the full breadth permitted by the patent laws. It is to beunderstood that the embodiments shown and described herein are onlyillustrative of the principles of the present invention and that variousmodifications may be implemented by those skilled in the art withoutdeparting from the scope and spirit of the invention. Those skilled inthe art could implement various other feature combinations withoutdeparting from the scope and spirit of the invention.

1. A system comprising: at least one memory storing computer programinstructions; and at least one processor configured to execute thecomputer program instructions which, when executed on the at least oneprocessor, cause the at least one processor to perform operationscomprising: obtaining, from a device in a vehicle, information relatingto a change made to a mixture while the mixture is being transported inthe vehicle; determining an expected value of a selected characteristicof the mixture based on the change; and causing a communication deviceto display a representation of the expected value on a display device.2. The system of claim 1, wherein the change comprises an addition of achemical to the mixture.
 3. The system of claim 1, wherein the mixtureis produced based on a formulation, the operations further comprising:causing the communication device to display a graphical representationof a gauge, wherein an indicator of the gauge indicates a differencebetween the expected value and a second value of the characteristicdetermined based on the formulation.
 4. The system of claim 1, wherein:the mixture is a concrete mixture; and the vehicle is a concrete mixingtruck.
 5. The system of claim 4, wherein the selected characteristic isone of slump, strength, maturity, and cost.
 6. A method of managinginformation, the method comprising: determining a change made to amixture during transport of the mixture in a vehicle; determining anexpected measure of a selected characteristic of the mixture based onthe change; and causing a communication device to display the expectedmeasure value on a display device.
 7. The method of claim 6, wherein thechange comprises an addition of a substance to the mixture.
 8. Themethod of claim 7, wherein the substance is one of water and a chemical.9. The method of claim 8, wherein the change comprises a first additionof a first quantity of the substance to the mixture; the method furthercomprising: receiving information relating to a second addition of asecond quantity of the substance to the mixture; and determining theexpected measure of the characteristic of the mixture based on thechange and the second addition of the substance.
 10. The method of claim9, wherein determining an expected measure of a selected characteristicof the mixture based on the change comprises examining historical datarelating to the effect of the change on the selected characteristic. 11.The method of claim 6, wherein: the mixture is a concrete mixture; andthe vehicle is a concrete mixing truck.
 12. The method of claim 11,wherein the selected characteristic is one of slump, strength, maturity,and cost.
 13. A system comprising: a storage adapted to store: datarelating to one or more changes made to a mixture; and at least oneprocessor adapted to: determine a change made to a mixture duringtransport of the mixture in a vehicle; determine an expected measure ofa selected characteristic of the mixture based on the change; and causea communication device to display the expected measure on a displaydevice.
 14. The system of claim 13, wherein: the mixture comprises aconcrete mixture; and the vehicle comprises a concrete mixer truck. 15.The system of claim 13, wherein the change comprises an addition of asubstance to the mixture.
 16. The system of claim 15, wherein the changecomprises one of an addition of water and an addition of a chemical. 17.The system of claim 16, wherein the change comprises a first addition ofa first quantity of water to the mixture; the at least one processorbeing further adapted to: receive information relating to a secondaddition of a second quantity of water to the mixture; and determine theexpected measure of the characteristic of the mixture based on thechange and the second addition of water.
 18. The system of claim 13,wherein the at least one processor is further adapted to: determine anexpected measure of a selected characteristic of the mixture based onthe change by examining historical data relating to the effect of thechange on the characteristic.
 19. The system of claim 13, wherein: themixture is a concrete mixture; and the vehicle is a concrete mixingtruck.
 20. The system of claim 19, wherein the selected characteristicis one of slump, strength, maturity, and cost.
 21. A system comprising:at least one memory storing computer program instructions; and at leastone processor configured to execute the computer program instructionswhich, when executed on the at least one processor, cause the at leastone processor to perform operations comprising: obtaining, from a devicein a vehicle, information relating to a measurement of a firstcharacteristic of a mixture made while the mixture is being transportedin the vehicle; determining an expected value of a second characteristicof the mixture based on the measurement; and causing a communicationdevice to display a representation of the expected value on a displaydevice.
 22. The system of claim 21, wherein: the mixture is a concretemixture; and the vehicle is a concrete mixing truck.
 23. The system ofclaim 22, wherein the first characteristic includes one of temperatureand water content.
 24. The system of claim 23, wherein the secondcharacteristic is one of slump, strength, maturity, and cost.
 25. Amethod of managing information, the method comprising: obtaining, from adevice in a vehicle, information relating to a measurement of a firstcharacteristic of a mixture made while the mixture is being transportedin the vehicle; determining an expected value of a second characteristicof the mixture based on the measurement; and causing a communicationdevice to display a representation of the expected value on a displaydevice.
 26. The method of claim 25, wherein: the mixture is a concretemixture; and the vehicle is a concrete mixing truck.
 27. The method ofclaim 26, wherein the first characteristic includes one of temperatureand water content.
 28. The method of claim 27, wherein the secondcharacteristic is one of slump, strength, maturity, and cost.